Newly acquired Kawasaki UX150 with C-Controller

    Hello everyone !


    After aquiring an used 1999 Kawasaki UX150, I looked for informations online and this forum has been my main source of informations. Thank you very much for that !


    I picked it up recently, expecting to salvage some parts of it to use on other projects. But first, I plugged it in. To my surprise the controller started and even the tactile screen lit up and worked. With errors of course (I'm willing to bet he didn't move in a few years). After playing around a little and bridging a limit switch wire that was cut, all the errors were cleared and the beast moved ! I manually moved all servos individually and they all worked fine (entirely thanks to the informations and manuals I found on this forum, thanks again). However, a few days ago while proudly showing my new machine to anyone willing to see it, I started to notice the tactile screen seemed to have trouble booting. I played with the luminosity, cable and plug and it worked, until it didn't...


    Here are the symptoms:


    - Tactile screen entirely black and unresponsive.

    - Error light comes on every time after boot, clears up using the button and doesn't come back on until next power up.

    - Interbus RDY led blinks green, FAIL led lit up red.

    - All of the leds on the 1HP board are on.

    - I can still power the motors up using the deadswitches and motor power button. It lights up and can hear them beeing powered up


    What I've tried:


    - Pushing on the tactile screen with motors unlocked, where the commands used to be. But no response at all (neither movement nor beeping).

    - Checking the cable with a multimeter, all pins in the plug appear to connect with the pins on the connector inside the tablet and no pin seems to be shorted with another or ground.

    - Removed 1HP board, cleaned with electronics cleaning spray and reinstalled.
    - Playing with the cable, plugging and unplugging the tablet, playing with the luminosity. Whispering sweet words, intimidation, bargaining, begging... :winking_face_with_tongue:



    Since I can't see the error code now I'm not sure what to do, maybe I can plug in a monitor and a keyboard somewhere but I'm not sure where. And I know just because it looks like a VGA doesn't mean you should plug a VGA in it. I've looked into the manuals but didn't find my answer in the hundreds of pages yet.



    Here is a photo of the machine, don't hesitate to ask if you want more pictures or want me to give you more infos !



    Thanks in advance and have a nice day !






    (Sorry for the mess but I'm moving my equipment to a new and bigger place soon)

    Welcome to the forum...... :beerchug:

    Long time lurker and now getting your feet wet resurrecting a good old work horse......Love it.

    Looks like you've made some nice progress until the 'blank screen'.......shame, but all is not lost.


    Looks like an infamous ex Jaguar system to me.


    No VGA output signals from the controller, as the teach pendant is the VGA and just communicates to the controller via RX+,R-,TX+,TX- comms lines as well as the hard wired emergency stop, deadmans.


    Only way to get some comms is via RS232 to see boot up information, however most ex jaguar controllers had the RS232 port disabled as a default.


    So, we need to know:

    1. What is the Controller variant - Should have a rating plate on the controller probably C42.

    2. Usually on power up you get a 'small beep' or 'pink' from the teach pendant, do you hear anything.

    3. Turn off the lights in the room, check for the internal backlight - small strip of light at the bottom.

    4. Can you show a picture of the inside of the controller - Card rack file more importantly.

    5. Do you have any experience with using KCWin or KRTerm applications?

    6. Have a look here to download them and some connection instructions are included.

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


    If you can get online via a laptop using KCWin32, KCWinTCP or KRTerm, you will see the error produced, the fact you can still energise the motors and release the breaks proves there's nothing real fatal going on.


    So it should be limited to the teach pendant backlight tube, teach pendant inverter board (it has a small 0.5A fuse on it), teach pendant 1FT board failure, teach pendant harness (intermittent fault due to twisting, harness, X1 > XHP-CN4 (internal harness connecting teach pendant to 1HP board or CPU board (but I doubt it is the CPU).


    I would persevere with getting online first and determine what error is being produced and also obtaining a full file save whilst you can, so that you have a recent backup of it.


    If you are based in the UK, maybe I could give you a business visit for some assistance and training.. :top:

    Hello Kwakisaki,


    Thank you for your fast answer and warm welcome !


    I also think it is a minor issue since the motors power up and only the teach pendant appears to be irresponsive.


    I'll be following your instructions and updating you to try and fix the beast.


    Here is what I can provide immediately:


    Quote from kwakisaki

    1. What is the Controller variant - Should have a rating plate on the controller probably C42.

    It is a C42 variant indeed, I will send you the complete plate information soon.


    Quote from kwakisaki

    2. Usually on power up you get a 'small beep' or 'pink' from the teach pendant, do you hear anything.

    I don't hear anything from the teach pendant.


    Quote from kwakisaki

    4. Can you show a picture of the inside of the controller - Card rack file more importantly.

    I had this on hand :winking_face:


    Quote from kwakisaki

    5. Do you have any experience with using KCWin or KRTerm applications?

    Absolutely none, as I mentionned my first intention was to dismantle it (I was planning to use the servos for a lathe CNC conversion). However since the robot appears to be in running state, that would be a waste of a nice machine... And I can definitely find a use for it.


    I've had to use a few AS commands to clear the errors early on (postion and software limits reset), I have some experience with programming in general and it was not complicated with the manual on hand.


    Quote from kwakisaki

    6. Have a look here to download them and some connection instructions are included.

    I've checked, another amazing upload from you ! Thank you again ! I don't have a null modem cable on hand but I'll get one soon (usb variant is ok ?). I'll go fishing for a working laptop in the pile :grinning_squinting_face:.


    Coming soon:

    1. I'll check the backlight tonight, it's too bright at this time.


    2. I'll let you know when I have connected a laptop to the controller.



    Thank you for offering to visit, that would have been lovely... However I'm from Belgium.It's not that far so maybe we can arrange something in the future ?

    Thank you again and have a nice afternoon.

    Quote from DoesItExist

    However I'm from Belgium.

    Heehee........each time an ex Jaguar (from the UK usually) C Controller appears on the forum, I always ask and they always appear to have departed the UK.


    Maybe I should think of moving to mainland Europe...... :hmmm:


    Thanks for the additional information, and yes if you don't hear the little 'beep', 'pink' sound then the TP is not receiving any power from the AVR via the 1HP board, XHP-CN4 to X1 harness, or X1 to TP or possibly the internal board.


    The supply is 12V+ and I know the AVR is providing that power, or else you wouldn't be able to energise the motors as the Servo board would produce an error.


    I would take apart the TP, back cover slides off after you remove all the screws and you'll be able to see the connector to the board.

    I would disconnect that and remove the complete harness.

    Completely stretch it out, then go down it feeling for kinks and cuts (very common intermittency).

    Then just bring the 2 connectors together (without curling the cable too much) and DVM measure them for continuity - using the information I sent you.

    I would also look inside the metal connector, it has been know for some of the pins to push in slightly when plugging it into the controller causing disconnection.


    If it is the internal board (1FT board is quite easy to replace), that maybe a pain to obtain as a separate item and you may just have to get a replacement complete unit from Ebay or something like that......may not be cheap though.

    Quote from DoesItExist

    I don't have a null modem cable on hand but I'll get one soon (usb variant is ok ?). I'll go fishing for a working laptop in the pile :grinning_squinting_face: .

    You may have trouble with the RS232 route as ex Jaguar used to disable the programming port on the front and on the CPU board in the controller.

    RS232 programming cable can either be a null modem cable or simply a poor mans lead using 3 wires.

    2>3

    3>2

    5>5


    USB adapters are fine, but rarely cross over Tx and Rx lines, so either way you would need a null modem or poor mans lead if you go down the RS232 connection route and the port hasn't been disabled.


    Which leaves the Ethernet (from your image I can see the port just peeking out on the CPU board.

    But that means you would need a cross over ethernet cable (if going peer to peer), if going through a switch/router, then a patch lead would suffice.

    Also the problem of finding out the IP Address.


    If it is ex Jaguar, they used to print the IP Address to the teach pendant with yellow tape, so if that's present, that's the IP Address I would use to try out first.

    Never used any apps to sniff network traffic I'm afraid, but I think wire shark could be used to locate the IP Address.

    Hello again kwakisaki,

    I have a bit of an update:


    - The complete model n° is C42F-A001.

    - I've looked for the backlight and there is none, consistent with the lack of power then.


    I have already opened up the pendant and disconnected the harness to check continuity, and all pins were connected. I think I'll check the voltage in and out of the inverter board and the fuse to make sure it's not dead.


    The cable I bought specified RS232 and "for connection to PLC board 2->TxD 3->RxD 5->GND". If the RS232 port is disabled anyways I'll use the ethernet port.


    I didn't see any tape but I've used wireshark quite a bit during my studies so there's a good chance I'll remember how to use it quickly :top:


    Turns out I don't have a working laptop on hand so I'll buy one second hand as quickly as possible.


    Thank you for your support, I'll keep you updated !


    PS: I have no idea what you mean by ex jaguar systems. They used to be in the jaguar factory ? I'm curious...

    PPS: My controller has yellow tape with "Halewood refurbished unit" on it, Maybe it rings a bell.

    The inverter board has a small SMD fuse 0.5A, if that blows then obviously no backlight, so that's worth ruling in or out, but I suspect it will be fine.


    cguenther has just had something similar happen to his teach pendant.

    Was working, then came to it and appeared dead.

    He thought it was something to do with it being very cold in his environment and left it warm up for a bit and hey presto, it came to life.


    Never heard of temperature as being an issue, but in his case it did the trick.

    Maybe worthwhile trying that out.

    Quote from DoesItExist

    PS: I have no idea what you mean by ex jaguar systems. They used to be in the jaguar factory ? I'm curious...

    PPS: My controller has yellow tape with "Halewood refurbished unit" on it, Maybe it rings a bell.

    Exactly.

    There is a Jaguar Automotive Plant at Halewood in Liverpool (UK) and in Solihull (UK), I used to visit there whilst I was employed at Kawasaki UK carrying out service and training tasks, so they are well known to me.


    They had a huge strip out of all Kawasaki C Controllers a few years ago and now they are appearing on the 2nd user market and several people (like yourself) who have acquired one visit the forum.

    Hello again kwakisaki,


    I've went down the cable and seen neither kinks nor cuts. However when I tried plugging it in I did hear a little beep, very low volume but upon trying multiple times I did hear it everytime I plugged the harness in.


    I've also checked the pins and they where all in place and I was not able to feel any of them moving abnormally inside the plug.


    I wanted to test the inverter board but i'm very ill equipped to test for small circuit boards. I only managed to test the pink and yellow cables and measured 0.6VAC.


    I'll let the pendant warm up in my house for a moment and try it again in the evening. We'll see...


    Still looking for a laptop, I'll let you know when I have one at the ready !


    Quote from kwakisaki

    Exactly.

    There is a Jaguar Automotive Plant at Halewood in Liverpool (UK) and in Solihull (UK), I used to visit there whilst I was employed at Kawasaki UK carrying out service and training tasks, so they are well known to me.


    Thank you for the info, I'm very curious about this robot's history. Since I picked it up at an auction I had no idea where it came from, I at least have a trail now !


    I'll update you again this evening

    You would be best served using a silly scope (Oscilloscope) to look at the output not a DVM and you can get a 'little tickle' from it if you accidently touched the outputs with your fingers, so be careful around any inverter boards in general.


    I have noticed using some DVM's, if you just hold place one probe on the white/yellow wire, if it is functioning, you can see a small arc between probe tip and connection point.


    The 'pink' is generated from a small piezo inside the TP.

    Remove the back cover and power up - the 'pink' will be louder then.

    This will mean power is there and the TP is probably working and the controller powering up.

    You will also see more clearly at the bottom if the backlight is on or off.

    If you hear the 'pink' and no backlight, then could well be the inverter board at fault, or the backlight may have burned out AFAIK.

    Yes, as a matter of fact it's when I had the back cover off that I noticed the 'pink' and I do see a small arc when I probe the first pin of the connector with the white wires (5x) there is absolutely no backlight.


    Also I tried warming it up but it made no difference :sadsmiley:

    Quote from DoesItExist

    I do see a small arc when I probe the first pin of the connector with the white wires (5x)

    That shouldn't happen, that small connector is the power and logic supply to the inverter board.

    On the other side is the output to the CCFL - with the 2 wires, that is where I was referring to when you get an arc.


    If the fuse is showing no continuity, then it's possible the PWM transistors have failed.

    Just get standard 0.5AF glass fuse, break the glass, remove the wire and bridge the fuse on the inverter board and see what happens, it may just be a popped fuse.


    If it's the CCFL backlight that's burned out, these can be replaced but requires full disassembly of the TP and LCD screen assembly and therefore requires some good manual dexterity as well as keeping the LCD components super clean.


    I have replaced a CCFL in my time and just measured the diameter and length of the CCFL tube and got a stock one from a supplier that had the correct dimensions and got it working again, but took me that long, I've never attempted one again.


    So that may be an option if the CCFL is burned out.


    I would try and locate another one whilst you can.......I have a local source here in the UK that have plenty of these - 2nd user of course with cosmetic damages etc.

    If you want a contact, let me know and I'll send you it over via the 'conversation'.

    Hello again,


    I've got a laptop, crossover eth chable and managed to sniff the ip address of the controller !


    I ran errlog and this is the result:

    >errlog

    1-[23/01/29 20:16:44 (-1401)Amp over current jt 5. ]

    2-[23/01/29 20:16:43 (-1401)Amp over current jt 5. ]

    3-[23/01/29 20:16:42 (-1401)Amp over current jt 5. ]

    4-[23/01/29 20:16:42 (-1401)Amp over current jt 5. ]

    5-[23/01/29 20:16:41 (-1401)Amp over current jt 5. ]

    6-[23/01/29 20:16:40 (-1401)Amp over current jt 5. ]

    7-[23/01/29 20:16:40 (-1401)Amp over current jt 5. ]

    8-[23/01/29 20:16:39 (-1401)Amp over current jt 5. ]

    9-[23/01/29 20:16:38 (-1401)Amp over current jt 5. ]

    10-[23/01/29 20:16:37 (-1401)Amp over current jt 5. ]

    11-[23/01/29 20:16:36 (-1401)Amp over current jt 5. ]

    12-[23/01/29 20:16:35 (-1401)Amp over current jt 5. ]

    13-[23/01/29 20:16:33 (-1401)Amp over current jt 5. ]

    14-[23/01/29 20:16:31 (-1401)Amp over current jt 5. ]

    15-[23/01/29 20:16:30 (-1401)Amp over current jt 5. ]

    16-[23/01/29 20:16:13 (-1401)Amp over current jt 5. ]

    17-[23/01/29 20:16:10 (-1401)Amp over current jt 5. ]

    18-[23/01/29 20:16:09 (-1401)Amp over current jt 5. ]

    19-[23/01/29 20:16:07 (-1401)Amp over current jt 5. ]

    20-[23/01/29 20:16:02 (-1401)Amp over current jt 5. ]

    21-[23/01/29 20:13:02 (-2226)FTP)AUTO-SAVing failed. ]

    22-[23/01/29 20:13:02 (-586)Time out. ]

    23-[23/01/29 20:02:05 (-1401)Amp over current jt 5. ]

    Press SPACE key to continue.

    24-[23/01/29 20:01:48 (-1215)INTER-BUS status error. no parameter ]

    25-[23/01/29 20:01:47 (-2226)FTP)AUTO-SAVing failed. ]

    26-[23/01/29 19:53:37 (-1401)Amp over current jt 5. ]

    27-[23/01/29 19:53:21 (-1215)INTER-BUS status error. no parameter ]

    28-[23/01/29 19:53:20 (-2226)FTP)AUTO-SAVing failed. ]

    29-[23/01/29 19:49:32 (-1401)Amp over current jt 5. ]

    30-[23/01/29 19:48:19 (-1215)INTER-BUS status error. no parameter ]

    31-[23/01/29 19:48:18 (-2226)FTP)AUTO-SAVing failed. ]

    32-[23/01/29 19:46:55 (-2226)FTP)AUTO-SAVing failed. ]

    33-[23/01/29 19:46:55 (-586)Time out. ]

    34-[23/01/29 19:35:41 (-1215)INTER-BUS status error. no parameter ]

    35-[23/01/29 19:35:40 (-2226)FTP)AUTO-SAVing failed. ]

    36-[23/01/29 19:27:41 (-1401)Amp over current jt 5. ]

    37-[23/01/29 19:27:16 (-1215)INTER-BUS status error. no parameter ]

    38-[23/01/29 19:27:15 (-2226)FTP)AUTO-SAVing failed. ]

    39-[23/01/29 19:25:59 (-1401)Amp over current jt 5. ]

    40-[23/01/29 19:20:48 (-1215)INTER-BUS status error. no parameter ]

    41-[23/01/29 19:20:47 (-2226)FTP)AUTO-SAVing failed. ]

    42-[23/01/29 19:19:05 (-1215)INTER-BUS status error. no parameter ]

    43-[23/01/29 19:19:04 (-2226)FTP)AUTO-SAVing failed. ]

    44-[23/01/27 00:12:47 (-1215)INTER-BUS status error. no parameter ]

    45-[23/01/27 00:07:26 (-1401)Amp over current jt 5. ]

    46-[23/01/27 00:07:09 (-1215)INTER-BUS status error. no parameter ]

    Press SPACE key to continue.

    47-[23/01/26 19:09:38 (-2226)FTP)AUTO-SAVing failed. ]

    48-[23/01/26 19:09:38 (-586)Time out. ]

    49-[23/01/26 19:08:23 (-2226)FTP)AUTO-SAVing failed. ]

    50-[23/01/26 19:08:23 (-586)Time out. ]

    51-[23/01/26 18:57:08 (-2226)FTP)AUTO-SAVing failed. ]

    52-[23/01/26 18:57:08 (-586)Time out. ]

    53-[23/01/26 18:45:54 (-1215)INTER-BUS status error. no parameter ]

    54-[23/01/26 18:45:53 (-2226)FTP)AUTO-SAVing failed. ]

    55-[23/01/26 18:34:57 (-1215)INTER-BUS status error. no parameter ]

    56-[23/01/26 18:34:56 (-2226)FTP)AUTO-SAVing failed. ]

    57-[23/01/26 00:02:24 (-1215)INTER-BUS status error. no parameter ]

    58-[23/01/26 00:02:23 (-2226)FTP)AUTO-SAVing failed. ]

    59-[23/01/25 00:09:42 (-1215)INTER-BUS status error. no parameter ]

    60-[23/01/25 00:09:41 (-2226)FTP)AUTO-SAVing failed. ]

    61-[23/01/25 00:01:06 (-1215)INTER-BUS status error. no parameter ]

    62-[23/01/25 00:01:05 (-2226)FTP)AUTO-SAVing failed. ]

    63-[23/01/23 00:10:30 (-1215)INTER-BUS status error. no parameter ]

    64-[23/01/23 00:10:29 (-2226)FTP)AUTO-SAVing failed. ]

    65-[23/01/23 00:08:52 (-1215)INTER-BUS status error. no parameter ]

    66-[23/01/23 00:08:51 (-2226)FTP)AUTO-SAVing failed. ]

    67-[23/01/22 23:44:44 (-1215)INTER-BUS status error. no parameter ]

    68-[23/01/22 23:44:43 (-2226)FTP)AUTO-SAVing failed. ]

    69-[23/01/22 17:35:22 (-1215)INTER-BUS status error. no parameter ]

    Press SPACE key to continue.

    70-[23/01/22 17:35:21 (-2226)FTP)AUTO-SAVing failed. ]

    71-[23/01/21 22:10:05 (-1215)INTER-BUS status error. no parameter ]

    72-[23/01/21 22:10:04 (-2226)FTP)AUTO-SAVing failed. ]

    73-[23/01/21 22:06:52 (-1401)Amp over current jt 5. ]

    74-[23/01/21 22:06:50 (-1401)Amp over current jt 5. ]

    75-[23/01/21 22:06:33 (-1215)INTER-BUS status error. no parameter ]

    76-[23/01/21 22:06:32 (-2226)FTP)AUTO-SAVing failed. ]

    77-[23/01/20 17:43:48 (-1504)Position envelope error jt 5 ]

    78-[23/01/20 17:42:13 (-1308)Motor power off. ]

    79-[23/01/20 17:41:52 (-1504)Position envelope error jt 5 ]

    80-[23/01/20 17:38:54 (-1602)Limit switch signal line disconnected. ]

    81-[23/01/20 17:37:58 (-1602)Limit switch signal line disconnected. ]

    82-[23/01/20 17:37:18 (-1215)INTER-BUS status error. no parameter ]

    83-[23/01/20 17:37:17 (-2226)FTP)AUTO-SAVing failed. ]

    84-[23/01/20 17:34:39 (-1215)INTER-BUS status error. no parameter ]

    85-[23/01/20 17:34:38 (-2226)FTP)AUTO-SAVing failed. ]

    86-[23/01/19 22:34:53 (-1602)Limit switch signal line disconnected. ]

    87-[23/01/19 22:34:52 (-1602)Limit switch signal line disconnected. ]

    88-[23/01/19 22:34:43 (-1602)Limit switch signal line disconnected. ]

    89-[23/01/19 22:33:29 (-2226)FTP)AUTO-SAVing failed. ]

    90-[23/01/19 22:33:29 (-586)Time out. ]

    91-[23/01/19 22:32:14 (-2226)FTP)AUTO-SAVing failed. ]

    92-[23/01/19 22:32:14 (-586)Time out. ]

    Press SPACE key to continue.

    93-[23/01/19 22:31:59 (-1602)Limit switch signal line disconnected. ]

    94-[23/01/19 22:31:35 (-1602)Limit switch signal line disconnected. ]

    95-[23/01/19 22:31:26 (-1602)Limit switch signal line disconnected. ]

    96-[23/01/19 22:30:49 (-1602)Limit switch signal line disconnected. ]

    97-[23/01/19 22:22:24 (-1602)Limit switch signal line disconnected. ]

    98-[23/01/19 22:22:01 (-1602)Limit switch signal line disconnected. ]

    99-[23/01/19 22:21:46 (-1602)Limit switch signal line disconnected. ]

    100-[23/01/19 22:20:59 (-2226)FTP)AUTO-SAVing failed. ]

    >ERROR (-1401)Amp over current jt 5.



    UPDATE on the state of the controller:

    When I tried to clear the errors today it didn't work, by looking at the log I believe the error that I could clear earlier was the interbus status error. The new error is Amp over current jt 5, this one doesn't clear. I've checked the manual and it seems to be and hardware issue, I'll look further into it in the coming days.


    Regarding the TP issue

    I'll try to bridge the fuse just like you said, maybe this evening if I get some free time.

    Interbus error is being generated by the Interbus card and will be due to the fact there is no network is in place.

    Unless your using Interbus, then it'll be better to pull that out and disable the fieldbus/unallocate the interbus thus remove the annoying repeating error.


    The 1401 is strange to see, I don't recall that error should appear until the request to energise the motor(s) and brake release is made.


    Is that error being produced permanently, or are you trying to drive the robot?


    That is an error generated from the power block and the current sensor detecting >144% than the correct current specification.

    Usually attributed to:

    - Short circuit motor.

    - Short circuit on the harness to the motor.

    - Short circuit on the umbilicals from controller to robot.

    - Short circuit in the power block transistors for the mentioned axis.

    - Faulty 1GB.


    Disconnect all the umbilicals and see if the error goes away.

    You will receive other errors when you do this, so it's just a test to see if that specific error is removed.

    You will have to press the reset button several times to get a picture of other faults.

    Hello kwakisaki,


    It's been a while but I just had time to work on the robot a little. Here's an update:

    - I've bridged the fuse with a fuse wire as you adviced and the TP turned on !

    - I'm still having the current overflow error on JT5. It is strange indeed because I have not tried to power the motors on. The error is thus produced permanently, and appears to have started when I plugged the laptop with the ethernet crossover cable...


    Now that the TP is back on, I'll check to see if I did not cause a short circuit in the controller somehow. I'll also try to remove the umbilicals and check if I can clear the error.


    I'll let you know when I've made some progress.


    Have a good day !

    Quote from DoesItExist

    I've bridged the fuse with a fuse wire as you adviced and the TP turned on

    Nicely done......hope you used low current fuse wire, or else you could end up with a smoking TP.

    Could just of popped without any real cause, but just keep your eye's open for any repetition of it.

    Quote from DoesItExist

    The error is thus produced permanently, and appears to have started when I plugged the laptop with the ethernet crossover cable...

    Nah, that won't be associated with that.

    Current sensor is inside the power block assembly (block at the bottom with a 1GB board mounted to it).

    That fault is being generated from that and from experience, the issue is usually attributed to an internal component fault.

    However, definitely check the external umbillicals for shorts, robot internal harness for shorts and also JT5 motors stator resistances.

    Ok soooo, I've just been trying a few thing on the controller here's what happened:


    - I've started the controller and the error was still there. I opened the front pannel and pressed clear error. To my surprise, the error cleared. I then tried to power up the motors and the light was flickering on and off. I noticed the emergency button was pushed on the TP, reset it and tried to power up the motors again. The error poped up again... I then noticed the emergency button was pressed on the controller too and reset it as well. I tried playing with the door and clear error for a while, to no avail.


    - I then started unplugging the umbilicals one by one and got many errors that would not clear. With the JT5 error appearing and disappearing for no apparent reason... Removing all umbilicals did not clear it definitely tho. And at some point the TP just powered off entirely and I decided I was in over my head and needed to report :grinning-smiley:


    Based on the inconsistency of the error I'm thinking of something like a short-circuit in the controller box that depends on the position of a cable, although I'm really confused at this point... :hmmm:



    Quote from kwakisaki

    Nicely done......hope you used low current fuse wire, or else you could end up with a smoking TP.

    Could just of popped without any real cause, but just keep your eye's open for any repetition of it.


    Yup, I picked the wire of a 0.5 A Fuse as you advised, and with the screen going black again I'm thinking it comes from and underlying Issue.



    Quote from kwakisaki

    Nah, that won't be associated with that.

    Current sensor is inside the power block assembly (block at the bottom with a 1GB board mounted to it).

    That fault is being generated from that and from experience, the issue is usually attributed to an internal component fault.

    However, definitely check the external umbillicals for shorts, robot internal harness for shorts and also JT5 motors stator resistances.


    Yeah, I was thinking I might have pinched a cable while opening the controller or sth. I'll be looking for a short to ground on the pins of the X3 -> X5 plugs now I guess. Do you know where I can find the wiring diagrams for C-controllers so I have an idea where to look ? I'm guessing the issue is inside the controller since the error doesn't clear with all the umbilicals unplugged...


    I'm feeling stupid for only thinking about it now but there is an entire wire harness that's disconnected since I received the robot (you should be able to spot it at the bottom of the controller picture). At first I tought It was ripped off during transport but then I noticed the connectors had been bridged. Since there is a molex type connector missing on the side of the controller I figured it was just for the missing controller and forgot about it. Now I thinking it might have been wise to let you know sooner...


    Have a good evening and night !

    Quote from DoesItExist

    I picked it up recently, expecting to salvage some parts of it to use on other projects. But first, I plugged it in. To my surprise the controller started and even the tactile screen lit up and worked. With errors of course (I'm willing to bet he didn't move in a few years). After playing around a little and bridging a limit switch wire that was cut, all the errors were cleared and the beast moved ! I manually moved all servos individually and they all worked fine (entirely thanks to the informations and manuals I found on this forum, thanks again). However, a few days ago while proudly showing my new machine to anyone willing to see it, I started to notice the tactile screen seemed to have trouble booting. I played with the luminosity, cable and plug and it worked, until it didn't...

    I think we need to go back to the start as (no offense intended), you are talking/writing about many things here and to suddenly go from 'the beast moved' to the 'TP and Amp errors', seems very strange to me.


    So, can we rewind.


    Can you:

    - Take a picture of this 'limit switch wire that was cut' and describe where this was.

    - The molex connector your referring to is X15 which is Jaguar Interbus and Field safety circuit.

    - The blue wires loose near the grey terminal strip connect to X15 and are usually terminated at TB2.

    - TB2 (grey terminal strip) has many jumper wires inserted in place of X15.

    - Take a good close up picture of TB2 (the long grey terminal strip) and post it.

    - If you are not using TB2, then that is the reason the black jumper wires are there.

    - Did it arrive to you with those black jumper wires terminated.


    Have you checked here for further documentation, my post #9 contains a troubleshooting manual which contains the pinout for the umbilicals.

    X5 is the umbilical which contains JT5 UVW and ground lines.

    C-Series Documentation & Manuals - Manuals, Software and Tools for Kawasaki Robots - Robotforum - Support and discussion community for industrial robots and cobots (robot-forum.com)


    If you wanted a speculative guess regarding amp error from my perspective.

    As you managed to move the robot before, it wouldn't be too impossible to conceive that the internal harness on the arm to JT5 could be damaged.


    Now on UX Series arms, the minor axis (JT4, JT5, JT6) motors are all the same (back of JT3 structure).

    I would swap the connectors between one of the other axis (grey connector not encoder).

    *** DO NOT TRY AND MOVE THE ROBOT ***

    Just power up controller and see If the error moves to the other JTx.


    If it does not change the error to another JTx:

    - Internal harness/umbilical/power block.


    If it does change the error to another JTx:

    - Probably the motor.

    Hello kwakisaki,

    No problem with going back to the basics.


    Here is a picture of the limit switch cable that was cut.

    You can see it hanging with the wires twisted two by two. To determine what wires to connect together I opened the other limit switch on JT1 and checked the continuity with a DVM in the opened and closed state. I then reproduced it based on the color code of the cable and the error cleared.


    This cable, I'm fairly certain, was going inside one of the limit switches of JT1. The rest of the cable is entirely missing, but the limit switch itself is intact. It was probably ripped off at some point when the robot was moved since the terminal connectors were still inside of the limit switch and its mounting plate was bent.


    I'll make a second post so I can send you the picture of TB2.

    Quote from DoesItExist

    To determine what wires to connect together I opened the other limit switch on JT1 and checked the continuity with a DVM in the opened and closed state. I then reproduced it based on the color code of the cable and the error cleared.

    :top:


    FYI

    Arm limit switches are in series with the safety circuit for motor power.

    If they are incorrect, you will more than likely pop F1/F3 (small plastic window fuses) on the 1HP Board and unable to get motor power on......Always worth checking them though.


    If you do trigger a limit switch whilst moving the robot, motor power will turn off and can only be turned on again, whilst pressing and holding the limit switch override button the 1HP Board, then you can use the TP to drive the joint off the limit switch and then release the override button.


    Fairly certain, that limit switch won't have any impact on the JT5 amp error......Good, good.

    Quote from kwakisaki

    The molex connector your referring to is X15 which is Jaguar Interbus and Field safety circuit.

    Alright !


    Btw the plug that has an entirely missing connector is X14, I'm using it to let the ethernet cable through. I think I'll 3D print a plate to prevent moisture and dust from getting in.


    Quote from kwakisaki

    - The blue wires loose near the grey terminal strip connect to X15 and are usually terminated at TB2.


    In the future, I would like to do something with those wires so they're not hanging freely in the controller. Can I plug them back in or will that cause errors and I need to make a "shorted plug" for X15 ?



    Quote from kwakisaki

    - TB2 (grey terminal strip) has many jumper wires inserted in place of X15.

    - Take a good close up picture of TB2 (the long grey terminal strip) and post it.

    Here goes:



    It's obstructed by the wire harnesses, so this is the best I could do ! If you need another picture, let me know.


    Quote from kwakisaki

    - If you are not using TB2, then that is the reason the black jumper wires are there.

    - Did it arrive to you with those black jumper wires terminated.


    Yes, a lot of the connections on TB2 are just bridged with jumper wires, I'm guessing it's used to provide I/O for interactions with other equipment (just like in your amazing youtube videos :top: ).


    The jumper wires are all unterminated, I thought of putting ferrules on them but I didn't see any of the wires on TB2 beeing terminated so I went the lazy way and left it as is...


    Quote from kwakisaki

    Have you checked here for further documentation, my post #9 contains a troubleshooting manual which contains the pinout for the umbilicals.

    X5 is the umbilical which contains JT5 UVW and ground lines.

    C-Series Documentation & Manuals - Manuals, Software and Tools for Kawasaki Robots - Robotforum - Support and discussion community for industrial robots and cobots (robot-forum.com)

    I downloaded the file and started going through it printing the relevant informations, thanks !


    Quote from kwakisaki

    If you wanted a speculative guess regarding amp error from my perspective.

    As you managed to move the robot before, it wouldn't be too impossible to conceive that the internal harness on the arm to JT5 could be damaged.


    I did a quick check of the wire harnessed going to JT4-5-6 and they looked mint. I don't think the issue will be on the robot side since I only moved it slightly in every direction (it's on a pallet). So I'll start checking on the controller side then go to the robot side. Also, the motors were still powering up after the issue with the TP, but I wasn't able to move the robot with the TP beeing dead.


    Thank you for all the infos, I'll check the pins on X5 to check if there Is one that is abnormally shorted to ground.

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