C-Series controller for Kawasaki FS 10E, servo board communication error after reinitialization without backup!

No idea just how stable it will be for you as >20 year old robot system will not have the optimization capabilities compared to that of current technology, so you may not be able to achieve the precise results your expecting.

Plus the motion planner and memory limitations as well as the 'lack of rigidity' available on industrial robotic arms may be difficult to overcome.

Looks in very good condition though inside and out.............

Well, you definitely need to ensure you have replaced BOTH battery assemblies or else you are going to constantly 'fire fighting with it'.

Have you replaced both assemblies:

1. RAM located on the left side of the card rack inside the controller.

2. Encoders located behind the rear panel of the robot where the umbilicals are connected to.

In addition to this can you answer the following:

1. Can you make a file save to your laptop using RS232 cable and KCWin32.

2. Does it boot up to full status screen.

3. What errors are displayed currently - List full error code and explanation.

4. What errors can be reset and what are left remaining.

5. Can you post a screenshot of the data contained in Aux Function 90.

Usually that error is because no communication is occurring between the 1GB servo board (mounted to the to the large power block located underneath the card rack and the 1GA board.

Can you post image of LED's displayed on that board - You should be able to see any through the cut out window?

Can you check ALL connections are firmly connected to the 1GB?

Can you check ALL connections to the motherboard - left side of the card rack?

I recommend disconnecting them and reconnecting when checking.

What is that 'grey cable' I see in the picture, where is that going to, that's not a Kawasaki cable?

Also, have you access to DVM so that you can measure voltages on the 1GA board test pins?

Having the initialization sheets is good, at least things can handballed in if needed.

Why have you removed the 1GA board........the RAM battery is now disconnected and more than likely corrupted everything.

Plug everything back in and get it back to where you were.

This time (see attached), provide led status of 1GB board.

Provide screenshot of status screen again.