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... 8o



    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)

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  • 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:


    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.


    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.


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

    I had this on hand ;)


    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.


    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 :D.


    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.

  • 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.

    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 :D .

    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.

    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 !


    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:

  • 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'.

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