Kawasaki robot motor not turning on.

This is good information.............

However, because of 5 years of storage it is very possible RAM batteries have become exhausted too.

These are located inside the controller and are attached left side of card rack.

Before doing much else, need to confirm:

- Encoder Batteries are good - which you have done.

- RAM Batteries are good - which you haven't mentioned or may not be aware of these until now.

- Do you have any previous file save backup or data sheets (usually taped inside door).

- What is your experience with Kawasaki for setup and load/saving.

Ah, ok that is why you still have encoder battery error as encoder batteries are located in FS030L Robot.

So you will also need to replace these too, they are same type as you already change.

Encoder errors will always prevent motor power due to safety.

In order to access them:

- Power off Controller

- Remove black rear plate on robot (where all harnesses connect to).

- Behind you will see 1HG board and battery attached.

- Replace this and reconnect rear cover and power back up.

- Error should now be able to be reset.

When you have done this, we need to know what errors are permanently displayed.

Reset error many times until you find errors not clearing and provide these (include no. description).

I suspect controller may need to reconfigured/reinitialized, but we should do this after encoder battery is replaced.

This could be 'permanent' problem on the 1GA/1HA CPU board and may require a replacement.

However, let's assume is ok and is just possible corruption.

Please access auxiliary functions from pressing (Menu) and selecting Function button.

Navigate to Aux 90 and provide screenshot of display.

Ok, so the good news is I have copies of the current AS/SV firmware should they be required to reinstall.

As you have no backups, then loss of existing data is not a consideration, so you need to carry out a hardware initialization.

This effectively wipes and recalls/reloads the current AS/SV firmware into the 1GA/1HA board.

(however, I do suspect the AS is corrupt....but we'll see).

Attached is procedure, please carry out Part 1 only (ignore step 1.) and provide results.

Yes, looks like either board is damaged or corruption, but I suspect corruption.

Have you got a PCMCIA card available in the size range of 4Mb to 32Mb?

Firmware requires to be sideloaded using teach pendant and inserted PCMCIA card.

As controller is old, drivers and compatibility for PCMCIA cards is dated for back when controller was released.

So cards today are xxGb in size and these will not work, even if re-partitioned compatibility issues occur.

Kawasaki always recommended Sandisk as good compatibility and below are basically ones that are usually compatible:

SanDisk Compact Flash CF Card 16 32 48 64 96 128MB SDCFB White Label with BOX | eBay

SanDisk Compact Flash CF Card 16 32 64 128 256 MB SDCFB Industrial + Case | eBay

If you can locate something identical or very similar, I can send you files to reload.

No problem.

When RAM batteries are exhausted it is like robot dementia.

Data get's muddled and can therefore lead to problems.

From what you've described (assuming the controller was fully functional 5 years ago), then I doubt the 1GA board is damaged, but this is a possibility of course 5 years ago that the 1GA board was damaged etc.

So from what you've described, I am assuming it is data corruption and not actual on board component damage.

So if you can locate a suitable card, and if we can get the AS firmware back in, then it's a fighting chance of getting it back working again.

Yep, let us know when you're in a position with a card (you will also require an adaptor card too) and I'll get the files over and we can pick it back up..............

Give me half an hour and I'll send them in zipped folder to you via 'conversation' on your forum account.

Check your conversation out for zipped folder and information.

Top right of screen..........conv.JPG

Your issue relates to the AS flash and therefore that could be an attribute to the issue.

You could try making a file save using RS232 and KRTerm/KCWin32 application available here for download:

Kawasaki Online Terminal Editors - Manuals, Software and Tools for Kawasaki Robots - Robotforum - Support and discussion community for industrial robots and cobots (robot-forum.com)

However, as you've already wiped the controller, there is nothing previously worth saving so you may as well crack on uploading the firmware and see how it goes.