D3x Controller basic configuration setup for repurpose

Quote from ArcadeMachinist

However I was not able to zero J2, but that's just because I'm not sure extending J2 that far forward is safe with my current mount. I would prepare a better base for the robot then would do J2 again. "Better safe than sorry".

Yes, if the robot is not adequately mounted/secured then zeroing ALL joints at the correct posture at the same time can be difficult which is the below image posture:

You can also re-zero individual joints too using the same method, just by typing in the relative JT no. required.
So you could move JT3 to the vertical position (if you have room), re-zero JT2 and then move JT2 all the way back and re-zero JT3 as per the 2 below images.

       

Quote from ArcadeMachinist

Btw, should yellow warning light come on when motors are on?
Or it is in repeat-cycle mode only?

If you are referring to the lamp mounted on the arm, then this is the 'Servo On' lamp indicating the robot is live, even if it's not moving.
This is connected directly to the MC Unit X322.

Quote from ArcadeMachinist

p.p.s. Submitted Kawasaki documentation access request a week ago, no answer, id not activated

You may be better contacting KRI directly, as I mentioned they are very approachable and I'm sure they would supply all relative information.

If you can post a recent backup after zeroing - even if it's not 100% zero'd in then I can introduce you to the ArmID.

Just remember when you reload the backup in (after I have modified it), be aware any changes you make between sending it me and loading it back in may be lost.

Quote from ArcadeMachinist

Also replaced the arm battery today with (what seems to be) original one.
Old one was still working, but did not fit inside the mount hole.

If official Kawasaki battery is used then it is tie wrapped on the bracket and the replacement should fit no problem.

Quote from ArcadeMachinist

"Servos ON" warning light at the arm's elbow actually work, it is just someone replaced the lamp with LED, that is so dim, that is barely visible.

Lol.........
She prefers listening to Bruce Springsteen and 'dancing in the dark'.....(Sorry, couldn't resist).

Quote from ArcadeMachinist

I would re-calibrate J2, once the mount is ready.

No problem, re-loading the attached backup will not cause any zeroing issues with JT2.

Quote from ArcadeMachinist

Question: Is there a way for this controller to do a full backup (what is called "images backup" in Fanuc world).
E.g. CPU and Servo softwares included.

Unfortunately not.
AS and SV firmware is stored in the flash module mounted to the 1RA board - 1QJ board.
All other data is stored in volatile ram.
At power up AS is transferred to 1RA, SV is then transferred to 1RB, and then boots up.

The 1QJ board can be swapped to a replacement 1RA board (thus swapping firmware) and then the previous backup loaded (1RA replacement procedure in case of failure).

E controller onwards has a PCMCIA card fitted (internal hard drive) which an image can be made in the same way as Fanuc (image to USB) but not on earlier Kawasaki controllers.

So a recent file save is your 'get out of jail' - pretty much an AOA equivalent on Fanuc, except Kawasaki do include any file that can used to re-create the cell in KRoset like Fanuc have for Roboguide.

ArmID Box if installed:
- Introduced for UX and ZX Series arms initially and for all future arms and is FLASH memory.
- ArmID board used to store robot model, serial no, zeroing and storage of maintenance logs.
- Extended Arm DIO board used for local EOAT control and connections.
- Communicates via a serial data transmission line to 1RB board.
- 1RB board has several small dipswitches at the rear for ArmID communication and setup.

So simply the ArmID function is:
- Storing of arm data (arm data is checked with controller on power).
- If data is incorrect a 'question is asked' to use controller data or arm data.
- Allowing easier EOAT control and connectivity for DIO - ZX series has 8 outputs, 24 inputs.

Attached is your backup with the ArmID enabled which is progressive from the previous.

1. Put file on PCMCIA card as previous and place into controller.
2. Power up the controller and then load this file in as you did previously.
3. Ignore any errors and just reboot the controller.
- At bootup, you should see a variant of the following screen appear on the teach pendant:

- Select No. 2 Start by controller side data.
- After bootup, you may receive joint abnormality errors, servo changed warning etc.
- Reboot the controller again.
- Reset any errors and if check sum error is reported, use Aux 0803 and set effect and reset it.
- You should be error free and able to move the robot around freely as before.
- If all is good make a file save again at this point.
- This file save can be used to restore the controller to this state if required.
- After re-zeroing JT2, make a final file save and you have a basic configuration of your system.
- This file save can then be used to restore the system to this configuration.

As your hardware (1RB hardware and dipswitch settings) have not changed, then the information from the controller has been sent to ArmID and stored in the FLASH of ArmID.
Each time you bootup not only is communication checked but the information is compared and if different will result in a possibility of screens/errors (see attached arm id board manual).

Anytime you re-zero, the ArmID will automatically update the stored values from the controller.
Thus keeping a copy of the zeroing information which is used for comparison on bootup.

Go to Aux Func 06 and you should now see an additional IO option for ArmID IO.
This is where you would allocate your outputs and inputs for EOAT control and connectivity and wire accordingly (as per the arm id board manual).

Go to Aux Func 07 and you should see maintenance logs available to be written to, this is just a manual log entry function (that rarely is used by people) to enter and use a maintenance log of the controller for cases of: motor changes, re-zeroing and other maintenance issues.

Report back your results, if any issues, the provide screenshots of errors etc.....

Perfect, nice work................

You now have a basic configuration for your system where a previous backup was not available.
Appreciating the fact, it is not 100% mechanically aligned yet and further settings will be required to initiate and allocate any fieldbus configuration and other repurposing requirements.
Just make a file save for this stage too.

Quote from ArcadeMachinist

That is interesting, I did not realize it has I/Os on that board.

If there are two boards in the ArmID Box, then you will have extended DIO capability, but if there is just one board, then sadly it won't be available.

I did notice from your initial post that you had:
- Standard hardwire DIO board fitted in OP1 - 1GW (npn) or 1HW (pnp), usual is 1GW for US.
- 1JF fieldbus interface board with HMS ANYBUS Ethernet/IP fitted (This is Scanner Master)..

So yes, it makes sense they have installed an Ethernet interface and were more than likely (in the video) had an IO device coupled to that for the control of the gripper.

Quote from ArcadeMachinist

Let's say I want to put a spindle with CNC bit holder.
I can design (3D print prototype and then order machined) mount, no problem.

I have understanding, from your YouTube how to import tool model and define TCP.

I think converting G code to AS is also not a problem, I did some experiments in K-Roset on a virtual controller, and it works pretty good, of course my conversion is very basic and should be improved, as now it is basically LMOVE SHIFT (start_point BY x , y , z)

In my understanding I can use Ethernet/IP master board in the robot to control some Allen Bradley motor VFDs to run the spindle. Ex: AB Power Flex 70 series + 20-COMM-E module, should be able to talk E/IP.

So I can read where you're going with this, yes whether you use EIP or extended DIO for your EOAT control is purely down to your preference. EIP admittedly would be the logical thought.

Setting the tool etc, yes if you can apply your models in KRoset, create your routines, you can pretty much extract that information from KRoset and transfer it to the robot.

Quote from ArcadeMachinist

Meanwhile, if you can advise some reading on handling external I/O from the robot - that would be great.

Signals available are:
- Outputs (OX).
- Inputs (WX).
- Internal (INT).

Numerical addressing based on no. of signals used is:
- Outputs = 1 to 32.
- Inputs = 1001 to 1032.
- Internal = 2001 to 2255.

In Kawasaki you have simple AS commands for IO control:
- SIGNAL 2, 2001 turns on output 2 AND turns internal signal 2001 off.
- SIGNAL -2, 2001 turns off output 2 AND turns internal signal 2001 on.
- SIGNAL 2, -3, 4 turns on output 2 and 4 and turns off output 4.

- SWAIT 1002, waits for input 2 to be on.
- SWAIT -1002, 2001 waits for input 2 to be off AND internal signal 2001 to be on.
- SWAIT 1002, -1003, 1004 Waits for input 2 AND input 4 to be on AND input 3 to be off.

- Extended IO and Arm ID manuals are the only manuals for configuring and wiring IO.
- General fieldbus manual for setting the fieldbus.

Let me know if you require to use the fieldbus, just like the ArmID function, this will need enabling in software.

Would be interested to read or hear more about your G-Code conversion, so if you would like to talk about that privately, you can use conversation.

Check out your conversation, I have sent you a link available for 7 days.

Quote from ArcadeMachinist

In terms of if the I/O card (it is HW actually, not GW)

Are you sure?
2145 is 1GW and 2146 is 1HW (easy to mis-read), I would double check before wiring to be sure.
- 2145 = NPN = Standard scope of supply for North America Spec Controllers (D3x).
- 2146 = PNP = Standard scope of supply for European Spec Controllers (D4x).

Quote from ArcadeMachinist

I have checked the ArmID board, it does not have I/O extension.

Shame really, would have been good to have that, but it is an option at scope of supply.

Quote from ArcadeMachinist

If I add another HW/GW card, would it automatically map to 33-64 ans 1033-64?

Not in the literal sense as the addressing is not slot dependent, but board dependent.
If you refer to the troubleshooting manual it will explain a little more on this.

Basic IO card contains:
- 32 outputs and 32 inputs.
- Output is rated @ 100mA @24Vdc.
- Input is rated @ 10mA @24Vdc.
- Addressing jumper J2 located on rear of board for 1-32, 33-64, 65-96, 97-128 addressing.

So in order to add an IO board:
- Power off controller.
- Set applicable J2 jumper for address, if only 1 board then J2 should be 1-32.
- Insert board in any OP slot (usual to start lowest first as logical but no need).
- Power up controller.
- Navigate to Aux 0611.
- Set correct max inputs and outputs for the controller (this includes extended I/O if fitted).
- In your case just 32 and 32.
- Power cycle controller.
- If error relating to No.1 IO not installed, then board is faulty or addressed incorrectly.
- Wire input and output as per NPN or PNP version of board.
- Use external IO or troubleshooting manual to reference NPN or PNP wiring.

When it comes to adding fieldbus capability unless general fieldbus is enabled then fields and Aux Functions are not available.

Quote from ArcadeMachinist

Do I need to do anything specific to activate EIP board?

Yes, just like ArmID general fieldbus requires enabling then Aux Function and fields for fieldbus configuration and signal allocation will become available.

If you want this, post your recent backup and I'll modify it again for you.

Quote from ArcadeMachinist

Ah, now I understand how signal addressing configuration is done.
Like IRQ/DMA in old PCs

Keep that in mind and you'll smash Kawasaki in no time....

Quote from ArcadeMachinist

The board is 1HW, 2146.

Do not go off board print, there should be a white label on the back with red writing showing the part no.

Quote from ArcadeMachinist

Remaining question - if I configure one of ArmID boards I/Os as signal X
Would it just run it parallel with same numbered I/O pin on the 1HW/1GW?

I believe on D controller yes, but this really is not correct.
On E controller now, they have fixed this, so reflection does not occur.

In your case though:
- One 1GW/1HW board fitted.
- Extended IO board fitted.
- Aux 0611 set to 64 and 64.
- Allocate Arm ID signals starting at 33 for output and 1033 for input.

You will then have:
- 1GW/1HW allocated for 1-32 outputs and 1001-1032 inputs.
- Arm ID extended IO for 33-40 outputs and 1033-1056 inputs.

If only using 1GW/1HW without extended IO board then:
- Aux 0611 set to 32 and 32.
- ArmID allocation signals set to 0.

Attached is the file to load in for your fieldbus.
Reboot the controller after you have loaded it in.
After bootup you may see some errors until fieldbus is configured or board is not installed.
- You should see additional fieldbus options in Aux 06.
- You should see additional fields in Aux 0611 for Master and Slave.
- The general fieldbus manual contains the information for these additional fields.

If you have any issues and until your ready to use fieldbus, then use your previous backup to remove the fieldbus.....

Very strange.......
Try and rename the file to something smaller like file0.as

Quote from ArcadeMachinist

Available Fieldbus Ports should be configured from 0608.
In my case just one Port, as there is 1 daughter board.
Sometimes reading manuals helps

Perfect.................

After the load, I was going to go through those next steps to ensure you are error free.
You've taken it one step further with the fieldbus than I expected.....
So let's just review this.

Upon enabling fieldbus it automatically adds Aux 0608 Menu which includes the base fieldbus menu's and also the specific fieldbus menu's and also sets some default values too.

In your case, you already have:
- 1GW/1HW board fitted and working (no errors relating to No.1 IO board).
- ArmID board fitted but no extended IO board (no errors).
- 1JF and Master Ethernet/IP fitted to CN1 and jumpers are correct and boards are working.

Upon enabling the fieldbus, the default values for:
- Aux 060802 Assign ports to physical interfaces may not match your 1JF configuration.
- Unless your hardware configuration matches Aux 060802 then D4500 error(s) occur.
- This is good though, as it prompts you to make further settings.

I love it when people read the manuals..... +
You've already seen the mismatch between software and hardware and then adjusted Aux 060802 accordingly (Master and CN1).
- Master (4).
- Slave (0).

Power cycled the controller and now sitting error free.

The controller only communicates with fieldbus interface board via 1JF, NOT the outside world.
Only after this installation if a board fails or board removal will you get fieldbus related error(s).

All that is needed then is to read the manuals and configure the additional fieldbus settings to allocate and align your controller IO (local and fieldbus) to your application and device(s) using Aux 0608 Signal Allocations menu's.

Main areas will be:
- Aux 0611 - Set total number of IO for controller for local and master values to be used.
- Aux 060801 - This you will need to allocate for local and master and match total of Aux 0611.
- Aux 060803 - Check your device(s) if they need byte swapping and/or Big and Little Endian.
- Aux 060804 - You will need RSWorx I think to load in topology and IP Address settings.

If you need any further explanations on the fieldbus side or any issues, then shout out.
I assume you will work through this and read the manual when you have a device to install.

Quote from ArcadeMachinist

Question: Is there any internal point inside the controller cabinet where I can get any one of:
24v, 12v or 120Vac
I want to put industrial DIN Ethernet switch inside the controller box.
I know there is 120V outlet on the outside, but anywhere to tap inside?

There is only 24vdc available on 1KP pin 9 (24v) and pin 11 (0v) and that is fuse protected @ 1A.

Do not try and locate a 12Vdc point and tap into it or another 24vdc point, you could really damage your controller.

You can tap into the 120vac outlet for additional power as long as you don't exceed 3A.
It is common to do this:
- Install an internal PSU to provide >1A of 24vdc.
- Use this to power your switch and robot installed peripherals and also plug in a laptop.

At the moment though, you are ready to go from a basic setup and configuration on the controller, just a case of further development now.

Nice Work

ps...You have several progressive backups now, so plenty of 'get out of jail' data to return to.