Another BA-006L ex-welding robot

Recently got BA-006L ex-welding robot.
Original setup was with Fronius TP400i

Worked at an electric car factory, I suspect the same as greenman 's

Robot seems to be functional, but of course needs to be reconfigured first.

From what I understand there are 2 issues:
a) E9428:

It expects Cubic-S to be connected with E/IP to Allen Bradley GuardLogix safety PLC.
While I probably can source a dirt cheap used PLC, I do not see it reasonable to do, at least now.
I'm downloadin CS Configurator right now (it is slowwwww) to check out if external safety PLC can be unconfigured.
Or is it mandatory for Cubic-S?

b) E1427:
This one I would first take the steps from E Controller troubleshooting manual and if fails try to summon local Kawasaki Gods

First find: X313 is wired to an external "SAF1" connector, I guess originally it has a jumper in place.
Can someone confirm which pins should be jumpered? X313-A1 with X313-B1 for sure, but anything else?

E1427 goes away with just these 2 jumpered (as troubleshooting manual advises).

But I still can't get motor power to go on. Real motor power, virtual indicator on TP goes on.
But then it says "Turn on trigger".

DIAG screen shows this:

I'm not *yet* sure what are TRG1 and EX_TRG1 here.
Guess: Cubic-S intercepts TP's deadman switch trigger?
Not Cubic-S, this nice video shows Cubic-S is not wired to the trigger circuits.
youtube.com/watch?v=sdbFkAIe298&

But it looks like X205 X204 is actually branched and partially wired to SAF1 external connector.

I would have to remove 1VH and whatever is below it to see what is going on.

Here is SAF1 pinout.
Is it some Kawasaki standard, or a customized thing for a single customer?

There is also a circular SAF2 connector, but it is not wired to anything, just has a long harness inside, ending with bare wires, no connectors.

Connector, pictured below, bridges SAF1 with a high density connector that is stuck between main cpu cage and 1VH, I can not pull it out with out dis-assembly, I guess that is where X205 X204 is branched and trigger circuit is broken.

Indeed automotive!
They all are from the same electric car factory and came with a custom paint.
(Fanuc robots from the same factory also custom painted same color).

X204 is spliced.

Half going to external SAF1 XRTGC_n pins, half to Cubic-S XIN_1

Power to the robots!

1. Removed splice harness from X204
2. Unconfigured dedicated signals from E/IP signal numbers
3. Turned off OP_OUTCUBE, OP_CUBIC_S, OP_EIP_SAFETY
4. Disconnected Cubic-S harness from X7 and placed standard jumper.

greenman this might help you, except your +1 axis thing.

Quote from kwakisaki

Ford have a similar colour AFAIK.

Originally it was 100% owned by Ford, before they sold 90% shares and now keep 10%.
So that explains the color

Quote from greenman

What did you replace the 204 splice with?

You just remove it.

Original X204 connector is plugged into this splice cable and the splice cable goes into X204 port.
Just remove this extra cable and plug X204 directly where it is supposed to be.

I was playing with the robot today, turned back "on" Cubic-S with OP_CUBIC_S,
and then reading Cubic-S config with the CS-Configurator.
I did save the original config, then removed all network safety stuff it expects to find via E/IP.

I'm getting E9402, but I guess it is expected, as Jt2 and Jt3 were re-zeroed while Cubic-S was unconfigured.

The weird thing is I get "Torch interference" error on every power on.
It can come immediately on boot or 2 minutes later, robot is not even moving.
After resetting, it does not pop up again.

I did try to pull/push torch insert when it is really moving - and it does not produce any errors.

UPDATE:
I did invalidate all the limits for motion in Cubic-S too.
My biggest misunderstanding of the concept was:
When you invalidate "Constant monitoring area", you are basically saying there is no safe area, you are not disabling the feature. Then I looked at virtual safety switches diagram in CS-Configurator and realized that "CMA" is not disableable at all and must always have reference points configured. Other than that my Cubic-S is reconnected back to X7 and robot runs.

Can't yet test in repeat mode, I'm waiting for the key to arrive.

So I got my Teach/Repeat keys today and in the Repeat mode it always fails with "E6506 Torch interference".

I did read the torubleshooting guide for E0x E6506, but where exactly is the limit switch, I'm looking for?

The schematic is also pretty much ambiguous.

I'm starting to suspect that 1TW's CN3-B3 is not wired to X3-17.
I have traced it and checked connectivity all the way to the robot base.
Would open the base and see if it is spliced there for some extra Fronius safety.
But docs suggest it should not.

Cable runs all the way to J3 junction box.
There is a set of unconnected plugs, including the one where Torch Sensor ends up.

There are no cables going towards J4,5,6 except 2 motor cables and 2 encoder cables.
So, my guess, this robot does not have a build-in torch limit switch and was wired to Fronius.

I should figureout should it be just jumpered or smth else.
Or I can ask greenman



I guess shock sensor is always external?
Just can be different manufacturer.

Is it just a normally closed loop between +24V and SIG3?

Yes! Just founf it out myself
It actually was setup to get Torch interference signal from E/IP.
Set to 1000 and scrapped all other E/IP stuff.

Now it happily goes into Repeat mode.
However if I do
MC ZPOWER ON
DO LMOVE SHIFT(HERE BY 0,0,10)

It does nothing.
E.g. green "CYCLE" lits, but lamp on the robot does not.
And it does nothing.
Putting any other commands returns "(P1009) Program already running".


There are no background tasks, all cleaned up / killed.