Posts by DoesItExist

I connected the robot with an ethernet crossover cable but I plan on putting it online eventually. Here's the save file with the IP adress removed (I edited the extension to be able to upload it).

Hello again, it's been a while!

I was on a holiday then been busy catching up...

I indeed found it in virtual store (I meant to save in under C:\save but I'm working on a website and switched the syntaxes ).

Do you need me to upload the save file ?

Hello kwakisaki,

I made a save using the command:

"Save C://save"

I was expecting the to find the save in my PC but there's nothing so I guess it was saved in the controller's memory ?

PS: amp over current on JT5 is back

Hello kwakisaki,

Yes I checked and cleaned F5, I can connect the laptop to the robot so I'll make a save file and post it here as soon as it's done!

I have absolutely no room, I'm currently looking for a bigger shop but I'm not quite there yet...

I was planning on storing it until I get a bigger shop and enough room for it.

Hello kwakisaki,

I tried to activate joint interpolation but had an error saying "no program"...

I uploaded the videos:

Video 1

robot functionning until error 1504 while moving JT3

Video 2

robot functionning until error 1504 when moving JT4

Video 3

robot functionning until error 1504 when moving JT4. Inconsistent grumbling noise can be heard from the servor

Video 4

robot functionning until error 1504 when moving JT5

Video 5

Whirring sound heard from the servos

Video 6

Weird noise heard from the servos, brake engaging ?

All the errors 1504 are on JT5, no matter what servo was moving when the error occured.

I've been tring to clear the current overload for half an hour to get these videos, in the end I managed to clear it by:

-Unplugging X5

-Restarting the control box

-Pressing "clear errors" many times

-Once cleared, I plugged X5 back in

-Restarted the control box

Now the robot is running but the 1504 error pops up spontaneously. I didn't get the overcurrent error again yet.

I'm starting to consider trying voodoo magic

I'm providing 3x400V (measured approx 420V).

I managed to clear the issue and move it again, I took a few videos. I'll upload them this evening. I'm having the position envelope error after moving it a bit at the moment

While trying to clear the error I have unplugged X5 and noticed the error clears then comes back after an inconsistent amount of times (it's not clearing at all with X5 plugged in).

I tried the manual break release and hear them click I'll try to move them with a buddy as soon as I can

Yes it seems the more we search, the more we have to search...

I'm not seeing MCB F5 nor finding it in the troubleshooting manual. Can you help me locate it ?

I'm guessing It's an other movement mode I can activate by pressing joint interpolation in the teach block menu on the TP ?

I'm having difficulties clearing the error, I'll record a video as soon as the error clears and I manage to move it again

Hello kwakisaki,

I had plugged that baby in yesterday ! I took the measurements on the 1GB board and tweaked them to :

-12.10 VDC

12.10 VDC

5.05 VDC

I didn't know about the TP going sleep mode so that's probably what happened...

I plugged GB-CN10 out cleaned it and plugged it back in.

After that I restarted the robot and it worked for a while again. I played with JT5 as much as I could, then it locked again however the time I had a new error:

1500 JT5 of motor overload

Then it cleared it and started it again then had the error:

1504 position envelope error of JT5

Cleared it and the JT5 over current error popped up and wouldn't clear again...

When running the motor I noticed I heard suspicious noises but when I tried to record them but the JT5 error wouldn't clear again...

Ok, thank you !

I'll be checking all that tomorrow. Last update on the symptoms for tonight:

As I finished checking everything, I noticed the TP had blacked out again and restarted the controller. The TP came back to life and I had the Interbus error that cleared immediately and the JT5 error didn't pop up. It's getting pretty confusing...

Also checking the test pins on 1GB for good measure:

-12: -12.04 VDC

+12: 11.91 VDC

VCC: 4.95 VDC

I'm checking the 1GB board and CN10 is plugged in perfect, CN1 was half unplugged tho. I pushed it back in.

The DC voltages were :

-12.05 VDC

12.03 VDC

4.99 VDC

Here is a picture of the 1GB board with error and the LEDs on.

I now have the X5 Umbilical unplugged but the JT5 error keeps coming back.

Okay, I'm in front of the controller RN checking everything. Here is a picture of the damaged controller. The connector still has both pins to catch the lever, it only has a bit of play because it doesn't press on the casing all around but it's going nowhere.

A little update on the symptoms:

I started the robot a few times and it seems the error doesn't appear on "cold starts" I managed to move it a few times but the error inevitably pops up after moving it a while. Especially when moving JT5.

I cleaned the controller box with compressed air and insisted on the internal housings. I also cleaned them up with circuit cleaner and toroughly checked all the connections. I noticed the damaged connector has a bit of play but still don't think this is the issue.

I also checked XM3SA and it was plugged in securely, cleaned both sides with compressed air and plugged it back in.

I started the robot without any error but it still poped up a minute later and wouldn't clear again.

I'll try to find someone to megger the umbilical, we'll see...

Hello kwakisaki,

I've tried to remove the umbilicals on the robot side and still had the error, so it seems the issue is not on the robot but in the umbilicals or connectors. When removing the connector on the robot side I noticed it is damaged. However the damage seems to be superficial (a corner of the housing is broken off) and I haven't noticed any change plugging and unplugging it.

What I have noticed is that the error seems to be pretty inconsistent. Sometimes it comes back immediately after clearing, sometimes taking a few seconds, sometimes clearing completely (I was even able to move the robot at some point).I've played with the cable near the controller box and it seemed to influence the error. I'll keep playing around with the umbilical and connectors but the signs seem to be pointing to a short in the umbilical housing.

I've unwound the unbilical and searched for bumps or tears, there is a slight deformation near the connector on the control box side as if the cable was crushed, it doesn't seem that bad but it is the only suspicious place I can see.

I'm thinking about trying to shorten the cable a little myself or finding someone to do it for me.

Hopefully I'll be back with good news soon !

Hello again,

I did a bit more testing. since I don't have a megger, I tested the voltage on the 1GA board and everything was perfect.

I tried unplugging the umbilicals again and the JT5 error cleared. I plugged them back in, restarted the robot and got no error. I was able to power up the motors this time and started taking a video. I didn't move the robot and while filming I pushed on the open control box door and the JT5 error popped up again. I was the unable to clear the error.

Since I didn't move the robot and It seems the error popped up again when I pushed the door that moved the umbilical, I'm thinking the issue might indeed be a short in the umbilicals, probably near the connector or inside it.

I'll try unplugging the cables on the robot side to see If the issue is on the robot or in the umbilicals. I'll keep you update !

Here are the results of my tests so far,

I tried swaping the motors connectors, however I didn't have enough reach on the other cables so I left JT5 unplugged and plugged its harness on JT4 or 6 (the stickers are missing). This resulted in no change at all, the error was still on JT5 and I had no error for the unplugged motor. I tried clearing the error multiple times but it wouldn't clear.

I tested all the wires on the controller plug and harness plug with a DVM and none of them were shorted to ground. Also tested on the motor connector with the same result...

I think this might be an issue on a board or current overload sensor since the motors are not even powered up... I'm going back to the troubleshooting manual .

Quote from kwakisaki

The molex connector your referring to is X15 which is Jaguar Interbus and Field safety circuit.

Alright !

Btw the plug that has an entirely missing connector is X14, I'm using it to let the ethernet cable through. I think I'll 3D print a plate to prevent moisture and dust from getting in.

Quote from kwakisaki

- The blue wires loose near the grey terminal strip connect to X15 and are usually terminated at TB2.

In the future, I would like to do something with those wires so they're not hanging freely in the controller. Can I plug them back in or will that cause errors and I need to make a "shorted plug" for X15 ?

Quote from kwakisaki

- TB2 (grey terminal strip) has many jumper wires inserted in place of X15.

- Take a good close up picture of TB2 (the long grey terminal strip) and post it.

Here goes:

It's obstructed by the wire harnesses, so this is the best I could do ! If you need another picture, let me know.

Quote from kwakisaki

- If you are not using TB2, then that is the reason the black jumper wires are there.

- Did it arrive to you with those black jumper wires terminated.

Yes, a lot of the connections on TB2 are just bridged with jumper wires, I'm guessing it's used to provide I/O for interactions with other equipment (just like in your amazing youtube videos ).

The jumper wires are all unterminated, I thought of putting ferrules on them but I didn't see any of the wires on TB2 beeing terminated so I went the lazy way and left it as is...

Quote from kwakisaki

Have you checked here for further documentation, my post #9 contains a troubleshooting manual which contains the pinout for the umbilicals.

X5 is the umbilical which contains JT5 UVW and ground lines.

C-Series Documentation & Manuals - Manuals, Software and Tools for Kawasaki Robots - Robotforum - Support and discussion community for industrial robots and cobots (robot-forum.com)

I downloaded the file and started going through it printing the relevant informations, thanks !

Quote from kwakisaki

If you wanted a speculative guess regarding amp error from my perspective.

As you managed to move the robot before, it wouldn't be too impossible to conceive that the internal harness on the arm to JT5 could be damaged.

I did a quick check of the wire harnessed going to JT4-5-6 and they looked mint. I don't think the issue will be on the robot side since I only moved it slightly in every direction (it's on a pallet). So I'll start checking on the controller side then go to the robot side. Also, the motors were still powering up after the issue with the TP, but I wasn't able to move the robot with the TP beeing dead.

Thank you for all the infos, I'll check the pins on X5 to check if there Is one that is abnormally shorted to ground.

Hello kwakisaki,

No problem with going back to the basics.

Here is a picture of the limit switch cable that was cut.

You can see it hanging with the wires twisted two by two. To determine what wires to connect together I opened the other limit switch on JT1 and checked the continuity with a DVM in the opened and closed state. I then reproduced it based on the color code of the cable and the error cleared.

This cable, I'm fairly certain, was going inside one of the limit switches of JT1. The rest of the cable is entirely missing, but the limit switch itself is intact. It was probably ripped off at some point when the robot was moved since the terminal connectors were still inside of the limit switch and its mounting plate was bent.

I'll make a second post so I can send you the picture of TB2.

Ok soooo, I've just been trying a few thing on the controller here's what happened:

- I've started the controller and the error was still there. I opened the front pannel and pressed clear error. To my surprise, the error cleared. I then tried to power up the motors and the light was flickering on and off. I noticed the emergency button was pushed on the TP, reset it and tried to power up the motors again. The error poped up again... I then noticed the emergency button was pressed on the controller too and reset it as well. I tried playing with the door and clear error for a while, to no avail.

- I then started unplugging the umbilicals one by one and got many errors that would not clear. With the JT5 error appearing and disappearing for no apparent reason... Removing all umbilicals did not clear it definitely tho. And at some point the TP just powered off entirely and I decided I was in over my head and needed to report

Based on the inconsistency of the error I'm thinking of something like a short-circuit in the controller box that depends on the position of a cable, although I'm really confused at this point...

Quote from kwakisaki

Nicely done......hope you used low current fuse wire, or else you could end up with a smoking TP.

Could just of popped without any real cause, but just keep your eye's open for any repetition of it.

Yup, I picked the wire of a 0.5 A Fuse as you advised, and with the screen going black again I'm thinking it comes from and underlying Issue.

Quote from kwakisaki

Nah, that won't be associated with that.

Current sensor is inside the power block assembly (block at the bottom with a 1GB board mounted to it).

That fault is being generated from that and from experience, the issue is usually attributed to an internal component fault.

However, definitely check the external umbillicals for shorts, robot internal harness for shorts and also JT5 motors stator resistances.

Yeah, I was thinking I might have pinched a cable while opening the controller or sth. I'll be looking for a short to ground on the pins of the X3 -> X5 plugs now I guess. Do you know where I can find the wiring diagrams for C-controllers so I have an idea where to look ? I'm guessing the issue is inside the controller since the error doesn't clear with all the umbilicals unplugged...

I'm feeling stupid for only thinking about it now but there is an entire wire harness that's disconnected since I received the robot (you should be able to spot it at the bottom of the controller picture). At first I tought It was ripped off during transport but then I noticed the connectors had been bridged. Since there is a molex type connector missing on the side of the controller I figured it was just for the missing controller and forgot about it. Now I thinking it might have been wise to let you know sooner...

Have a good evening and night !