Another BA-006L ex-welding robot

Quote from ArcadeMachinist

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.

Sorry, I am a bit late to this thread. As you discovered, all Fronius communication is over ethernet. and Fronius has a torch collision detection mechanism with a magnetic connection between robot and the torch. If the torch collides it breaks the magnet pair, and the "torch interference" signal is given. Without a torch, or more specifically, without the torch side of the magnet pair, the system will always detect the "torch collision", as the circuit is always broken.

Without any ethernet comms, and therefore nothing to tell you that the magnet circuit is good or bad, I assume that the "torch interference" is by default 'high'.

Nice to read about "setting to 1000" being an override option - I didn't know about that.

Quote from ArcadeMachinist

p.s. Out of curiosity, when SIG3 (original torch interference harness that is wired to 1TW board) used with the real sensor - how to determine which signal is that?

Is there some document, that is describing that?

Good luck with that one.

Standard arc weld systems generally utilize 1TW with 1GN board mounted (for hardwired configuration) and the signals are routed via 1GN and not 1TW for arc related operations.

Coupled with the fact, AFAIK Kawasaki never really provided CN3 details, even back in the day where the now 1TW was back then a 1GW or 1HW board.

Also coupled with the fact yours is ex automotive and may be configured for an automotive standard not generic.

So it could take sometime to find.

However, saying that the troubleshooting manual does offer specific information regarding controller pinouts => robot and also internal machine harnessing, so you should be able to obtain some information, may take sometime though.

Search for 1TW, BA Series, XLS, XSOL,

Attached is a connection manual for BA006N arc installation which has some further details that may help.

Yours being ex automotive, may not match the standard documentation and to be honest even a search in the troubleshooting manual for 1TW and CN3 and also cross referencing the machine and robot harnessing and pinouts for the BA referenced controller has some but limited information.

CN3 on 1TW is one of those areas Kawasaki has not really kept up to date in the manuals regarding actual pinout, h