I have four identical RS03N arms in a teaching environment, and luckily I get most of my minor technical service requests at no cost. I had this problem once. The Tech Support Guy came in, "copied the setup" (whatever that means) from one of the other arms, transferred it to the trouble arm, re-boot/startup, calibrate, and went home. Don't know the cause, except that these arms are powered off and remain idle for long periods of time.
1. Turn off Power
2. Open E_Controller Upper Cover Plate
3. Find Dip_Switch (Blue square and white color). this switch near RS-232C port.
4. You can find all dip_switch set "Off" status.
5. Only No.8 Dip_Switch set to "ON"
6. Turn on Power
and T/P will be display wait user command for Initialize.
Initialize ?
0 : No
1 : System Initialize
2 : Factory Setting
Dip_Switch No.8 must be set "Off" before Next cold or warm reboot.
ah... still your T/P freeze status....
1. Turn off Power, Remove CF Memory card and Re-Install, Turn On
2. Replace another T/P unit.
3... Call Kawasaki A/S Team 
...
If you carry out a hardware reset - ALL data is lost including robot model, zeroing, user data which results in empty controller and cannot be moved until data is reloaded.
I have seen this occur when users power cycle controller too quickly and corrupts data on CF Card so when powering off, wait min of 5s before powering back on.
Below is procedure I have used to restore controller when data corruption has occurred and I have full file save available.
1. Have recent backup available on USB memory.
2. Power OFF Controller and apply Teach Mode or Emergency Stop.
3. Locate 1TA/1VA board and dipswitch bank (top left corner of board – bottom switch).
4. Set dipswitch No. 8 to ON…..all remaining to OFF.
5. Power ON Controller.
6. At Splash screen, type in 999 ; for initialization of all data and enter.
7. Type in 1; yes and enter.
8. Controller will complete boot up.
9. Controller will display errors relating to 'Failed to load robot model', ignore errors.
- Goto Aux 0804 (software Version) - No Robot Model/Serial No will be available.
- But AS and SV versions should be displayed.
- This confirms controller has successfully transferred AS and SV data.
- This confirms total hardware reset.
10. Load in last known backup from USB Memory – AUX 0202.
11. ACCEPT, YES, FORCE LOAD to ALL prompts on Teach Pendant during load.
12. After load, Power Controller OFF and remove USB.
13. Turn OFF dipswitch 8 on 1TA/VA (ALL dipswitches off for normal operation).
14. Power Controller ON.
17. Goto AUX 0804 and confirm robot name/serial no. is correct.
18. Goto AUX 0803 and select ENABLE reset Check Sum option.
19. Reset errors – should now be clear of errors.
20. In Teach, clear Emergency stop then manually drive robot to zero marks and confirm axis monitor screen for Joint angles at 0.
21. Use Check Mode to confirm a program (if available).
1. Turn off Power
2. Open E_Controller Upper Cover Plate
3. Find Dip_Switch (Blue square and white color). this switch near RS-232C port.
4. You can find all dip_switch set "Off" status.
5. Only No.8 Dip_Switch set to "ON"
6. Turn on Powerand T/P will be display wait user command for Initialize.
Initialize ?
0 : No
1 : System Initialize
2 : Factory SettingDip_Switch No.8 must be set "Off" before Next cold or warm reboot.
ah... still your T/P freeze status....
1. Turn off Power, Remove CF Memory card and Re-Install, Turn On
2. Replace another T/P unit.
3... Call Kawasaki A/S Team
Hi Robtics,
Thanks for your notes. I did that procedure Calling Up the Initialization Screen. After this procedure before Initialize of the system option 1 in the following step I was able to make a backup program. So I could have all robot data backed up. After initialization complete I download the full backup program and yesterday the robot started run again without any additional modifications required.
If you carry out a hardware reset - ALL data is lost including robot model, zeroing, user data which results in empty controller and cannot be moved until data is reloaded.
I have seen this occur when users power cycle controller too quickly and corrupts data on CF Card so when powering off, wait min of 5s before powering back on.
Below is procedure I have used to restore controller when data corruption has occurred and I have full file save available.Code1. Have recent backup available on USB memory. 2. Power OFF Controller and apply Teach Mode or Emergency Stop. 3. Locate 1TA/1VA board and dipswitch bank (top left corner of board – bottom switch). 4. Set dipswitch No. 8 to ON…..all remaining to OFF. 5. Power ON Controller. 6. At Splash screen, type in 999 ; for initialization of all data and enter. 7. Type in 1; yes and enter. 8. Controller will complete boot up. 9. Controller will display errors relating to 'Failed to load robot model', ignore errors. - Goto Aux 0804 (software Version) - No Robot Model/Serial No will be available. - But AS and SV versions should be displayed. - This confirms controller has successfully transferred AS and SV data. - This confirms total hardware reset. 10. Load in last known backup from USB Memory – AUX 0202. 11. ACCEPT, YES, FORCE LOAD to ALL prompts on Teach Pendant during load. 12. After load, Power Controller OFF and remove USB. 13. Turn OFF dipswitch 8 on 1TA/VA (ALL dipswitches off for normal operation). 14. Power Controller ON. 17. Goto AUX 0804 and confirm robot name/serial no. is correct. 18. Goto AUX 0803 and select ENABLE reset Check Sum option. 19. Reset errors – should now be clear of errors. 20. In Teach, clear Emergency stop then manually drive robot to zero marks and confirm axis monitor screen for Joint angles at 0. 21. Use Check Mode to confirm a program (if available).
Hi kwakisaki,
Thanks for your comments. Before get it back running again I got only one error with the Check sum which could the reset in the settings.
Thanks for feeding back your results.
- Looks like you were lucky, if reading your post is correct regarding obtaining a backup prior to initializing......I shall have to try that method, could save a lot of downtime.....
Welcome to the Forum....... 
Hi kwakisaki,
Thanks for your comments. Before get it back running again I got only one error with the Check sum which could the reset in the settings.
You can solve "Check sum error" follow next steps.
AUX 0803 (Menu -> System -> Sum Check Error Reset)
Check box move to Off.
and Press "ESC" button twice on T/P.
your E0903 error message will be clear.
but, When a Cold start (Turn off -> Turn On) system, that parameter will be automatically returning to On.
For F series controller,does anone know the procedure
I have the same problem with the initialization of the T/P For the D+ series controller does anyone know the procedure?
Welcome to the forum..........
Yes I do, but please start a new thread as the procedure is slightly different than E controller and to avoid confusion, a new thread should be started.
