Kawasaki RS010LA stuck at logo

OCTOCAT · May 26, 2020 at 1:48 PM

Hello friends. First of all - sorry for my english.

I am not familiar with robots. We have a Kawasaki robot, model RS010LA and today it stuck in Kawasaki logo. Errors what i've got:

e20 login: /rundaemon.sh: line 12: ./rnp: No such file or directory

./rundaemon.sh: line 15: ./plcsL No such file or directory

Tried to run fsck.ext2 and errors disappeared, but now I see only Kawasaki logo as in picture (captured it from VirtualBox, where I ran image of internal memory). Tried to login with dbg/dbg, but I don know what to do. errlog.el:

Code

.***************************************************************************
.*=== AS GROUP ===         : 
.*USER IF AS               : 
.*USER IF TP               : 
.*ARM CONTROL AS           : 
.*USER IF AS MESSAGE FILE  : 
.*USER IF TP MESSAGE FILE  : 
.*ARM DATA FILE            : 
.*KERNEL                   : 
.*DRIVER                   : 
.*RFS                      : 
.*=== SERVO GROUP ===      : 
.*ARM CONTROL SERVO        : ASVE08000002X 2013/08/01 18:11
.*SRV DATA FILE            : 
.*ARM CONTROL SERVO FPGA   : ASFE080000006 2012/05/10 20:04
.*
.*Cpu board type           : 
.*=== Maintenance Support ===:
.*Maintenance Support      : 
.*   [Shipment setting data] 
.*There is no Shipment setting data.
.***************************************************************************
.ERRLOG
   1 - [20/05/26 13:13:10 SIGNAL:00 MON.SPEED : 34 TEACH mode]
       (D0001)CPU error.(PC=05294502)
       OPERATION1:[20/05/26 13:13:09] ( Control Power ON )
       OPERATION2:[20/05/26 13:09:05] ( errorcheck 'error' )
       OPERATION3:[20/05/26 12:55:12] ( Control Power ON )
       OPERATION4:[20/05/26 12:52:14] ( Control Power ON )
       OPERATION5:[20/05/26 12:50:52] ( Control Power ON )
       OPERATION6:[20/05/26 11:00:06] ( Control Power ON )
       OPERATION7:[20/05/26 10:58:04] ( Control Power ON )
       OPERATION8:[20/05/26 10:54:54] ( Control Power ON )
       OPERATION9:[20/05/26 10:27:35] ( Control Power ON )
       ROBOT1:
        PROGRAM:serga6sht Step:0 Cur_Step:1 STATUS:STOP
       Current Pose
         JT1       JT2       JT3       JT4       JT5       JT6  
          0.000     0.000     0.000     0.000     0.000     0.000
       Command Pose
         JT1       JT2       JT3       JT4       JT5       JT6  
          0.000     0.000     0.000     0.000     0.000     0.000
       End Pose
         JT1       JT2       JT3       JT4       JT5       JT6  
          0.000     0.000     0.000     0.000     0.000     0.000

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Read that D0001 code is caused by defective AS or servo software/hardware etc.

Additional info:

Code

   [SOFT VERSION]                                                               
=== AS GROUP ===         : ASE_010100V2S 2013/08/06 14:52                       
USER IF AS               : UASE010100V2S 2013/08/06 14:52                       
USER IF TP               : UTPE010100V2S 2013/08/06 14:52                       
ARM CONTROL AS           : AASE010100V2S 2013/08/06 14:52                       
USER IF AS MESSAGE FILE  : MASE0100V2SEN 2013/08/06 14:29                       
USER IF TP MESSAGE FILE  : MTPE0100V2SEN 2013/08/06 14:29                       
ARM DATA FILE            : ARME010100V2S 2013/08/06 14:52                       
KERNEL                   : _KNL101900000 2012/07/13                             
DRIVER                   : _DRV103200000 2012/12/17                             
RFS                      : _RFS100800100 2012/07/27                             
   [SOFT VERSION]                                                               
RFS                      : _RFS100800100 2012/07/27                             
LOCAL SYSTEM BINARY      : _LSB101800000 2011/09/15                             
PROFILER                 : _PRF101400000 2012/07/30                             
Cpu board type           : 1TA                                                  
USER IF TP COMMUNICATION : TP-V0001                                             
MC unit control soft(MC1) : MCC00000001 2008/05/29 17:00                        
MC unit control soft(MC2) :                                                     
MC unit control soft(MC3) :

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**kwakisaki** · May 26, 2020 at 6:26 PM

Welcome to the forum...………

Quote from OCTOCAT

Tried to run fsck.ext2 and errors disappeared, but now I see only Kawasaki logo as in picture (captured it from VirtualBox, where I ran image of internal memory). Tried to login with dbg/dbg, but I don know what to do. errlog.el:

Don't know why you're bothering with all of that, doesn't mention anything like that in the troubleshooting manual, plus you could of introduced further problems.

CPU has crashed and the bootup sequence appears not to be executing/completing.

So either the CPU board is goosed or the data on the CF card is corrupt, unreadable.

So, if you have a backup, carry out an initialization procedure and reload the backup in (see attached).

If this isn't possible, then a new CPU board or CF card maybe required.

OCTOCAT · May 27, 2020 at 5:12 AM

I have seen this recommendation in other topic but I don't have a backup. Therefore I tried to fix CF (if it was corrupted) but it didn't work. Also I didn't know what is "AUX 0202" etc but have seen that when tried to connect from PC via some sort of terminal. Will try to find some information about robot, may be backup or something.

**kwakisaki** · May 27, 2020 at 7:37 AM

Quote from OCTOCAT

Therefore I tried to fix CF (if it was corrupted) but it didn't work.

I wish ALL users with ANY equipment, to read OEM manuals before assuming they already know alternative ways of recovery, problems can be amplified by not following OEM procedures.

This could also invalidate possible warranty or/and make it very difficult to troubleshoot.

Reading a manual, and following instructions by OEM can save a lot of time and effort.

Rule No.1 my friend...……..Backup, Backup, Backup....Never any excuse for not having at least one.

Three options for backing up.

1. AUX 0201 Save all data to external USB memory, or built in CF Card (recommendation is always USB).

2. KRTerm, KCWin - Save all data to PC.

3. CF image using Aux 0894 - save CF image to external USB memory.

If you don't have a backup, then you have limited options:

1. Check CPU board is fitted correctly - bent pins etc.

2. Check on CPU board if CF card is mounted correctly, bent pins etc.

3. Check (depends on version) for RAM Module not loose and secure.

4. Obtain another CPU board and insert current CF card - Just power it up, if CF is good you will be back operational - Then backup.

5. Obtain CF card from Kawasaki Distributor with preloaded OS and firmware and insert and power up, then rebuild configuration by hand entering.

6. If you can connect to PC using KRTerm (RS232) and access command prompt, possibly try and obtain backup by using SAVE command.

- Then try reinitialization procedure.

7.If you have no backup or any replacement to hand, only thing is to re-initialize.

- You will lose all you data, and will have to hand enter new configuration data from data sheets supplied with Robot.

- If after re-initialization, still stuck on logo then...……..CPU or CF requires replacing.

OCTOCAT · May 27, 2020 at 10:14 AM

Absolutely agree. They made me do it... No oem instructions, no backups, nothing. And I see the robot for the first time. There is only one man that can operate this robot and he didn't know the words like "maintenance", "backup" etc.

Trying to locate dipswitch bank on the 1VA board.

**kwakisaki** · May 27, 2020 at 10:36 AM

Attached shows the location.

These can be accessed without removing the board.

Switch No.8 to on for reinitialization, if it works, you have a lot of configuring, zeroing and re-programming ahead.

OCTOCAT · May 27, 2020 at 11:06 AM

I see

OCTOCAT · May 27, 2020 at 11:09 AM

This is it?

OCTOCAT · May 27, 2020 at 11:48 AM

Followed by your instruction. Robot is boot up, but I can't power on motor.

**kwakisaki** · May 27, 2020 at 11:56 AM

Did your backup not complete/hang during the 'transformation' save?

- A successful file save should display 'File Save Completed'.

You won't achieve motor power whilst the system is showing E-Stop Condition.

- Clear this and try again.

OCTOCAT · May 27, 2020 at 11:59 AM

I found another backup, named as "ex2circle.as", tried that too. No errors during saving or loading backup.

Quote from kwakisaki

You won't achieve motor power whilst the system is showing E-Stop Condition.

I will try. Also found some manuals.

**kwakisaki** · May 27, 2020 at 12:07 PM

Good man.

A backup of sorts at least puts you in a better position than having to re-configure/re-program from empty.

The bonus, is it appears you just had some data corruption on the CF now it's booting, so a 'bullet dodged' I think.

Check both E-Stops are released and also connector X7 on 1TR board should be either external E-stop wired in, or possibly is missing jumpers.

Check out External IO Manual to configure the safety circuits - this manual is part of the standard set you should receive with the robot.

(I've attached it anyway - check specifically Appendix 7.2 for the default jumper configuration as supplied for X7, X8 and X9).

OCTOCAT · May 28, 2020 at 8:49 AM

Everything seems fine. But when I have tried to move the arm - i get error. Something like "cannot move along straight line JT04 in this configuration". Then I tried to zeroing, switched to "joint mode", move arm to vertical position. All data looks almost like in photo, except JT04 was much smaller. Fixed that, tried AUX 503 also. But after that I get E6007 error - Wrist can't be straightened any more (Singular point 1). Some axis works fine, some - throwing similar errors.

**kwakisaki** · May 28, 2020 at 9:28 AM

The zeroing data on the sheets are values set at point of manufacture.

If any motor, encoder, gearbox or any other mechanical overhaul has been carried out since, it is possible those values will not be relevant anymore.

Those values should only be used when you know no mechanical overhaul operation has been carried out.

Zeroing procedure should always be:

Aux 050103, followed by Aux 050101 in that order.

Singularity errors are attributed to when you use a linear interpolation mode/command (Base, Tool) and cause the wrist JT5 to be in alignment with JT4.

Using joint mode does not create singularity errors.

When zero'd you should check each joints software limits using joint mode to confirm the working envelope for each joint.

Again, you should not receive any singularity errors in joint mode.

OCTOCAT · May 28, 2020 at 11:52 AM

I tried everything, still getting E6007 errors. In joint mode no errors. Tried to set up working area, base coords etc according to operation manual, but no luck. In joint mode everything works, in other modes - E6007 (tried to run program "in the air" for testing purposes - E6007 too, when arm trying to move).

**kwakisaki** · May 28, 2020 at 12:29 PM

Sounds correct...….But remember, we cannot see what you're doing...……..

Quote from kwakisaki

Singularity errors are attributed to when you use a linear interpolation mode/command (Base, Tool) and cause the wrist JT5 to be in alignment with JT4.
Using joint mode does not create singularity errors.

What are the postures you are trying to move to - angles of JT4, JT5 and JT6 and how - JMOVE, LMOVE.

Show a picture of the position you are trying to achieve.

Show an example of your code.

OCTOCAT · May 28, 2020 at 12:37 PM

Quote from kwakisaki

Show an example of your code.

I mean, I can't move the arm even manually in teach mode. For example I am trying to move they arm +X and immediately getting error.

OCTOCAT · May 28, 2020 at 12:42 PM

Can't attach multiple files.

Also when I am zeroing - I move they arm into vertical position, according to marks on all joints. Is that correct?

**kwakisaki** · May 28, 2020 at 12:48 PM

As I mentioned, your have JT5 (Wrist in alignment) - This is called singularity.

From this position, you cannot perform any linear moves.

Rotate JT5 approx. -5 deg in joint mode, then try again, it will move then.

When zeroing , ALL joints must be aligned to scribe lines - These are mechanical zero.

OCTOCAT · May 28, 2020 at 1:19 PM

What a stupid I am... Re-zeroed again, rotate JT05 and seems everything working. Will check tomorrow.

Kawasaki RS010LA stuck at logo

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