Repurposing BA006L with E01G-A001

    Hello. I acquired a used welding robot and after spending some time seeing if I could repurpose the existing code. Eliminating errors one at a time. But without any context I had little clue as to the system. I opted for a factory reset.
    the old system had a seventh axis and cubic-s which were preventing any manual robot motion.
    After factory reset (option 1) (not 2 or 99)

    No more cubic-s : i do intend to add that back in once I have the basics working.

    I changed the robot configuration from 7 back to 6 axis. This removed all the axis 7 errors.
    However I have one last error. E1342 which refers to the motor harness disconnected or thermal limit exceeded. (MC1)
    Is this still the 7th axis?

    I have a seventh axis for the system (the previous was rotary and I have linear RTU) but I am still ordering the matching connectors for the motor and encoder outputs of the E01controller.

    My question is. Should I continue to troubleshoot and dive into the lower regions of the controller? Or should I source the connectors and connect my 7th axis motor and encoder and then try to power up again.

    Thank you in advance.
    Here are some photos. (Perhaps too many)


    iCloud Photos - Apple iCloud

    Quote from greenman

    Hello. I acquired a used welding robot and after spending some time seeing if I could repurpose the existing code. Eliminating errors one at a time. But without any context I had little clue as to the system. I opted for a factory reset.

    So you have little clue, but opted to dump everything without realising just what you were dumping...........Why, why, why, why, why?

    Why did you not post here before dumping everything?

    I don't mean to sound harsh, but you have not made things easy for yourself.

    1. Was this system fully deployed and working and witnessed before you obtained it?
    2. What errors were you getting upon first power up before you dumped all the important stuff?
    3. Did you make a full file save or/and an image save before dumping all the important stuff?
    4. What manuals do you have?
    5. What Kawasaki experience do you have?

    Quote from greenman

    My question is. Should I continue to troubleshoot and dive into the lower regions of the controller?

    The answer is how can you do this as you stated above that you have no clue and the act of dumping the system, requires it to be rebuilt.......with no clue?

    My answer would be to attend a Kawasaki training as this forum is no substitute for:
    - Kawasaki basic operations training.
    - Kawasaki adding external axis and configuration training.
    - Kawasaki integration and configuring Cubic S training.

    What you should really try and do is obtain a known previous backup from the seller and reload it in.

    Hi - thanks for the response, here is some more info regarding your questions.

    Perhaps I was too harsh in my self-evaluation: I have completed the Kawasaki integrator training, and have some experience with an RS005 robot that I acquired to develop my skills with a vision-guided pick and place demonstration with conveyor tracking. The previous company I worked with used Kawasaki, but I was 'just' the Mech Eng on the project team, while now I am everything on the project. I don't have ethernet safety system experience or PLC implementation capability (yet), both of which were on this BA006L. I intend that this (bare bones) deployment will not have those capabilities (other than to talk directly to the Fronius power supply). That was my main rationale for the reset, rather than trying to re-establish those things. A clean slate to start from felt easier than trying to deconstruct 100's of lines of code from a robot that was part of a production line and needed a PLC and ethernet safety comms with hardware that don't have and don't want to implement...

    I did take a full backup before resetting - so I could theoretically restore it. I could send it to you privately for review, but for some reason, I feel hesitant to put somebody else work onto the internet without their permission. I have attached the backup with the programs stripped out. I have spent many hrs. with KTOOLS working through their code to decipher it, before making the reset decision. I also have the full suite of manuals (both from the integrator training and then updated ones from the download centre). I am waiting for a cubic-S course to be scheduled so that I can go on it.

    I did not see the robot working before purchase (from an industrial surplus company) - but it was working. I have no detailed knowledge of its previous life, other than it was used at RIVIAN as a welding system, and it had a Fronius welder. This is confirmed by Kawasaki with the serial number, and from reviewing the code that was still on the controller). The same welding system as I have acquired (also from the surplus reseller). I recently completed the Fronius integrator training for this project.

    The robot has about 1 000 hrs of operation (all the joints had different hrs of motion).

    For clarity - This was the process I that used to 'initialse' with option 1. (sorry reset was the wrong word).

    Post

    Re: Kawasaki E-Controller - initialization incomplete - Hardware reset

    1. Turn off Power
    2. Open E_Controller Upper Cover Plate
    3. Find Dip_Switch (Blue square and white color). this switch near RS-232C port.
    4. You can find all dip_switch set "Off" status.
    5. Only No.8 Dip_Switch set to "ON"
    6. Turn on Power

    and T/P will be display wait user command for Initialize.

    Initialize ?
    0 : No
    1 : System Initialize
    2 : Factory Setting

    Dip_Switch No.8 must be set "Off" before Next cold or warm reboot.



    ah... still your T/P freeze status....

    1. Turn off Power, Remove CF Memory card and…
    saberlars
    August 26, 2017 at 10:00 PM

    thanks for helping -

    My current plan of action is to source Harting connectors for the motor and encoder and connect up the 7th axis (once i find the wiring diagram)

    Here is the work on that so far... Link

    This was I fear a mistake to do...

    I changed the robot from a 7 axis to a 6 axis, to remove the errors associated with not having the 7th axis connected, all axis then needed to be zeroed (I will reset them when I can move the robot to the zero marks) but I have one more error before I can manually drive the robot - my starting goal for building up the system

    Quote from greenman

    I feel hesitant to put somebody else work onto the internet without their permission.

    :respect:That's a very respectful thing to consider indeed, but unless there's any specific restrictions in place, then I doubt it would cause any issues.....but :top: for respecting that.

    As you have a previous back though, it does provide you with a previous known configuration which you do not have to make public.
    You can use your 'conversation' link on the forum to privately exchange information.

    What I would consider doing is to:
    - return the hardware and connections to the state you received it.
    - Load your previous backup in after carrying out the hardware re-initialization.
    - Post the errors you are seeing and we can progress from there.

    I think we could then:
    - disable Cubic S option in software by means of a file load.
    - remove the connection to 1TR X7 and insert the default jumpers to X7.
    - This should just disable (not change) the Cubic S and remove Cubic S influences.

    What do you think......fancy giving it a shot?

    Thank you for the offer - I accept... :grinning_face_with_smiling_eyes:

    I had a productive time on the phone (zoom) this week with Fronius and with Kawasaki USA and received some more specific documentation describing the original application, and its setup, as well as an imminent quote for cabling to connect up the 7th-axis motor and encoder.

    My proposal is that any further troubleshooting effort is delayed until the hardware (cables and welding equipment) arrives. I will spend time in the new documents getting familiar with the K-Logic setup and the hardware signals, and I can install some of them in the interim.

    I will also find out how to undo the initialize - I suspect it is not as simple as loading the backup with KRTerm ... is it?

    Quote from greenman

    I had a productive time on the phone (zoom) this week with Fronius and with Kawasaki USA

    Excellent, I wish other visitors would consider contacting Kawasaki OEM, they really are very approachable and sometimes go above and beyond expectations.
    Sounds like your session was very productive.

    Quote from greenman

    I will also find out how to undo the initialize - I suspect it is not as simple as loading the backup with KRTerm ... is it?

    That's exactly how it's done or place the file onto a USB stick instead......you cannot undo any initialization as the data is gone for good.
    Just follow the correct procedure attached using a USB stick instead (not the one you followed earlier) and then let us know what errors she shows us.

    Also make an error log filesave afterwards, which you can attach to your post without worrying about the publishing of previous owners data.

    Project update just as a FYI -

    The plan is to connect up the 7th axis to remove the MC1 error before restoring the backup and tackling the remainder or the errors - I will also connect up the external systems as per the traced wires for the external plug, and wiring diagram that I was able to source for the original project (lots of time on the phone). And order and install the missing welding equipment for the system.

    Plan A (and plan F) - I identified the part numbers for the motor and encoder cables for the RTU and have a quote in hand from Kawasaki - 120 day lead time for the cable set.

    Plan B - I approached Harting for just the connectors to replace the incompatible plugs on the RTU cables and wire in correct plug pair. - 16 weeks lead time from Europe.

    Plan C is to go back to Kawasaki for just the connectors - they are used elsewhere on my robot, so I am hoping they have them as singles, not as a cable sets (long shot).

    Plan D is to replace the controller connector as well as the wire hood with a pair for each connection from Harting. (not ideal with unnecessary work)

    Plan E (in parallel with plan D) - scour the internet for compatible plugs (if anybody reading this in North America knows of sources with large stock please ping me - Digikey is my first stop this morning.

    Plan F - execute plan A and wait 120 days for cables from Japan.

    Here is some info on the connectors for those interested:

    Han 3A-gg-M25 | HARTING Technology Group

    And the insert as well.

    Han Q 7/0-M | HARTING Technology Group

    9120073001Han Q 7/0 male crimp insert (10A)16 Weeks
    9120009901Han male coding pin (for Q 7/0, Eco, Snap-in Grip Frames)4 Weeks
    192000314213A Hood Top Entry, Low Construction, w/ cable gland for 6…12mm cable16 Weeks


    similar issues with the motor power plug

    Han CD module, crimp male | HARTING Technology Group

    Han 10A Halterahmen für 1 Modul | HARTING Technology Group

    Han A Hood Side Entry HC 2 Pegs M25 | HARTING Technology Group


    9140073001Han 40Amp CD module Male crimp 16 Weeks
    9140000304Han-Modular Frame for One module (for Han 10A)16 Weeks
    1920010054610A Hood Side Entry, Single Lever, High Construction, M257 Weeks
    19000005091M25 Metal Cord Grip, NPB, for 9-16 or 13-18mm cable4 Weeks


    It’s the partners that plug into these on the rear of the E01 controller -

    Sounds like you've put this under a microscope now and explored all avenues available.
    Yes, here in the UK, Harting plugs, sockets, shells, inserts and crimps are all on long lead times from Europe (I believe Italy is the source).

    I would hunt around for 2nd hand Kawasaki dealers as I am pretty sure legacy Kawasaki systems utilize the same connectors and you may just land lucky and cheap......

    Is the controller E01?
    If so - can I ask you to make pictures of how that "Motor B" plugs are wired internally?
    When/if you would open the controller box next time, of course.

    I know the plugs and cabling are available as a kit from Kawasaki.
    But I suppose with 2000% markup :grinning_squinting_face:

    I might be getting the same BA006L ex-welding setup in a week or two.
    I know my controller does not have that extra axis connector, but also I know E01 supports 7th Axis "out of the box". Not sure I would ever need one, but who knows :smiling_face:

    Or is JT7 supposed to be connected via robot base?
    Checked out controller wiring, JT7 goes to the robot's base.


    EDIT:
    Robot seems to be functional, but it had Networked Safety I/O connected and I'm trying to figure out how to get rid of it. E.g. "Cubic-S Network Safety Input/Output" manual page 13/14 describes how to monitor it, looking for removing it.

    I guess it is controlled by
    OP_EIP_SAFETY ON -5309

    But only kwakisaki knows what should be set here :grinning_squinting_face:

    Quote from kwakisaki

    Lol....never used it but that's the OP I would disable first.
    In fact I would consider disabling Cubic S full stop, removing the harnesses (taking photo's first) and get it working without, then put it back in later.

    Disabling Cubic-S overcomes that.
    OP_EIP_SAFETY is not enough alone, there is also
    OP_CUBIC_S and OP_OUTCUBE
    Then jumpering X7 and returning the jumper to JP1 on 1TR - Cubic disabled.

    Trigger mystery still remains, but I would get into in today.
    Then would use CS Configurator to remove external safety PLC settings in Cubic

    Update time...

    recap:

    • I have disabled and bypassed cubic S,
    • as well as initialized the system (Controller off – dip_switch 8 to ON on the comms board, power on, initialize to 1 (system initialize), power off, Dip switch 8 back to OFF, power on)
    • to remove the previous owners code without deleting the robot setup.
    • i jumpered x313 A1-B1 to remove the need for motor on feedback from the RTU same as ArcadeMachinist ) (I did it on the 26 pin SAF1 plug that I have fly lead for)

    I am struggling and now need to reach out for assistance again.

    I thought my issue was due to the external axis not being connected. But I got the necessary harting plugs (its own saga) and it is now connected up but still the error persists.

    I can get it to two different error sets depending on the channel that I assign to the external axis on this page–


    For channel 7 – I get 4 errors encoder and software/configuration

    E1496 – JT7 axis servo parameters data does not support connected power block

    E1501 – JT7 code set in software do not support power block or servo software

    D1500 – Encoder misread error JT7

    E1035 – encoder response error (JT7)


    For channel 8 (the one I think it should be) I get 1 error –

    E1342 – motor harness disconnected or robot temperature exceeded limit.

    The troubleshooting manual pg 3-152 - 90206-1045DEN implies that it is in the robot arm - so i might be looking in completely the wrong place. And also not sure where to begin looking for a thermal line in the robot motor harness. But the fact that changing the external axis channel makes it go away makes me think I am looking in the right place. but there is no thermal line in the RTU motor harness, only 3 power phases and 2 brake wires. The encoder has 6 wires that plug into the board, I just maintained the 1..6 labels.

    The X314 pair of wires disappear down into the depths of the controller and I cannot follow them. so I don't know where they go...

    Something that will no doubt be my next challenge... I am a little perplexed by the axis/joint labels/numbering.

    The servo amplifier has 7 axis that go into the robot power plug x4 (x551-7) but I don’t know what the 7th axis might control on the robot, its only got 6 axis.


    Then I also have P/N 50607-0128 R02, external axis KHI amplifier for Kawasaki that goes to the external axis. I believe this is designated JT8? (pg 6 of the external axis addition manual 90210-1292DEC)


    The robot had this axis on a rotary axis initially (pic below)– and I need to re-configure it for the linear axis of the RTU. Which I started to do - I am not yet sure how to get the mm/bit as I have no info on the encoder (yet).

    robot-forum.com/attachment/40705/


    The external axis addition manual (90210-1292DEC) indicates that I should contact KHI for the correct settings, Which I have done.

    robot-forum.com/attachment/40704/


    The RTU has

    Motor 28 (50601-0128) R2AA2250ALCPKL5 kw

    I was unable to find any information about the encoder – but it has a separate box that looks like a battery backup. I have not checked the battery status yet… 6 wires in and only 4 onwards to the encoder. I just maintained the 1..6 lables when connecting to the E01 controller. Tracing the wires in the controller they appear to go into the Jt7? encoder plug


    As a last resort – should I consider removing the 7th axis completely from the system to be able to get the welding system commissioned and working in pararobot-forum.com/attachment/40704/robot-forum.com/attachment/40705/llel with getting the RTU functional? I haven't dug into how I would achieve that, as I would just have to undo it all afterwards.

    kwakisaki I restored the original configuration as you suggested I try, but there were 28847 errors in it.

    , and at least 4 pages of system errors on the TP .. so I immediately initialized the controller again and went back to my two options of 1 error for channel 8, and 4 errors for channel 7.

    Thanks - J

    Edited once, last by greenman (July 16, 2024 at 5:49 AM).

    Breaking news - Kawasaki have sent me a new file for the configuration.

    5.0kW MOD File for RTU EUR502ENT.

    They confirmed it would be for Channel 8 (as axis :smiling_face_with_sunglasses: to use with the external 100A KHI amplifier (internal axis 7 is only 30A, so the 5kw motor is too large)

    They didn't tell me if it needed to go anywhere special, or if anything other than KRterm is needed to load it... fingers crossed...

    Loaded up with aux function - it asked what axis - I said 8 and got an error... There isn't an 8th axis.

    Used the maintenance code to change the configuration to 8 axis, power cycle, now it can load to axis 8, but axis 7 gives me the usual set of errors.

    E1496 – JT7 axis servo parameters data does not support connected power block

    E1501 – JT7 code set in software do not support power block or servo software

    D1500 – Encoder misread error JT7

    E1035 – encoder response error (JT7)

    With an additional E0903 check sum error of system data that will not reset with AUX 0803 - [cannot clear check sum error, check the following command or auxiliary data, ZZERO (no zero for the new axis 8 perhaps?

    Indeed - zero'd the 7th (non existent) and new 8th axis and was able to reset the checksum error.

    Now to figure out how to remove the ghost 7th axis...

    Anybody got suggestions?

    An afternoon of trial and error circles - I still have one error.

    after disconnecting the 7th axis in AUX2002 and loading the new MOD file for the 8th axis which is configured for the 5kW motor - I still have the error that I started with.

    E1342 – motor harness disconnected or robot temperature exceeded the limit. (MC1)

    MC1 I thought referred to the external motor - and there is no thermal line to the RTU.

    I guess I need to look for a thermal line in the arm. So I need to search for a Pin layout for plugs X3 and X4 to see which is the thermal line.

    X314 disappears into the depths of the controller - so I don't know where it goes...

    I couldn't attach a save/full of the current status.

    Any assistance is appreciated.

    Quote from greenman

    I guess I need to look for a thermal line in the arm. So I need to search for a Pin layout for plugs X3 and X4 to see which is the thermal line.

    In the troubleshooting manual you obtained the information on the error code from contains all system and arm cable pinouts.

    Have you checked umbilical for damage?
    Just insert a jumper across the two pins from information in troubleshooting manual from inside the arm and see if the error is removed.
    If not, then the umbilical is likely damaged or pins in connectors not making contact between arm and controller.

    Thank you kwakisaki located all the pin outs and wiring diagrams. Checked all connectivity at all steps and …

    between pin1 of X314 and pin 69 of X4 there is no connection.
    Pins 69 and 70 are jumpered in the robot base. So it seems they are simply to check the cable isn’t sheared. There is no temperature check in this system.
    Is there a good reason not to jumper it directly at x314?

    Replaced the offending wire and no more errors.
    Yay…

    But, something I have never seen before… when I try move the robot with the TP I get

    “Turn on trigger”

    All I can find in the manuals is P1046 : turn on trigger switch.
    If anybody has some hints for me? Ta

    Found this thread. But it’s on a different robot and controller. Although the symptoms sound similar. And I have cubic s in the mix as well, although I thought I had disabled it.

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