Kawasaki C80 CPU error

    So it is proven that the array spray_dist_prg[x,x] has some corrupt data in there, whether this is down to software or hardware, this is still unproven.

    What I would do next is:
    - Uncomment step 21 and 22 in program buffer_record.
    - Leave steps 29, 32, 35, 38 and 46 in program buffer_record commented out.
    - Comment step 55 in program fill_buffer.

    Attempt a full controller file save and see if this completes.
    From what I can see, this should be successful and the only thing missing from the file save would be:
    - Program fill_buffer and all relative variables including the suspect spray_dist_prg[x,x] array and elements.

    Can you try this?
    Also, do you have a full backup prior to this which includes fill_buffer and spray_dist_prg[x,x] locations?

    Hello, I tried to do that procedure. Unfortunately with command save bak robot saved fill_buffer and I have CPU error during save transform values.
    Looking in the file saved I found another occurency in which robot uses the spray_dist_array. When I tried to change that program line I had this print on terminal: Fatal error (ref_cnt < 0). Unfortunately I forgot to do picture on that part.
    Robot didn't show me red lamp of error but I wasn't able to use terminal again until reebot it.

    Fortunately I found a backup of this robot, so I tried to use sys command and load backup without array (I've inserted later manually) and it seems work. I can do save and load without problem and for the moment I don't receive CPU error anymore. I will do more tests and in case I will update you.

    Thank you very much to your help and interest.

    It seems too good if everything is working only with sys and reload backup.
    Today I had again a similar problem. I tried to load one different program in Kawasaki and I get again the CPU ERROR. I tried to solve as last time using sys command, but I can't do that, I get another CPU error. This time the code is different (previously it is 00008008, now it is 00008010).

    It seems like some part of memory is broken. Is it possible to do something like hardware formatting? Can be good idea?


    I don't know what to do again. :loudly_crying_face:

    I did elude to this possibility in my first post.

    The next thing to try is not a software reset like your doing, but try a hardware initialization instead but I think this may not work too, but it's worth a try.
    Hardware initialization requires the CPU dipswitches set in a certain order and a full file save to be available to load back in.
    Warning though, after the initialization, the controller is unusable until your file save is loaded back in
    Procedure is attached.

    If it does not work then you are left with:
    - AS firmware may need reloading.
    - CPU board may need replacing (which will require AS, SV firmware)

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