Posts by kwakisaki

    Welcome to the forum.......... :beerchug:

    Just referencing the manual(s) information on those error codes and a logical thought process relative to the controller electrical design and hardware (not experience).


    SRVO-150 refers directly to the fan, but could be the result of another error or the fan itself.

    SRVO-154 also points to a SRVO-044 which is related to the DC supply of the amplifier(s) exceeding specifications.


    DC bus is derived from the incoming source supply.

    If the incoming supplies are unbalanced due to higher incoming phases, then the DC derived from this could be exceeding the specification values.

    I think each amplifier is supplied directly from the incoming mains, therefore this error could be amplifier dependent - The error code should also refer to a particular joint(s).


    In addition to this, whilst the robot is moving and joints are dynamically changing direction, speeds, acceleration and deceleration etc.

    The back emf (regeneration voltage) can cause the DC bus to exceed levels and therefore a regeneration discharge circuit is used to dissipate the excess DC over a resistor.


    So this error can viewed from a couple of perspectives:

    1. Is this error produced when the robot is stationary and not moving or energised.

    2. Is this error produced when the robot is moving.

    3. Is there a specific axis that is faulting out whilst moving, or stationary.


    If it is 1.

    - Definitely check the incoming 3 phase supply and also the output from the transformer.

    - It suggests one of your phases is not balanced and probably higher than acceptable values.

    - Definitely check the regeneration unit is wired correctly and not faulty.


    If it is 2.

    - Definitely check the regeneration unit is wired correctly and not faulty.

    - Check it the error is occurring around the same location(s) in T1 and Auto.

    - Slow the robot down and see if the error repeats itself or operates ok.

    - Check the load on the robot arm is not exceeding specifications.


    If it is 3.

    - Definitely check the regeneration unit is wired correctly and not faulty.

    - Change the amplifier.


    I would not be try and overcome the issues by changing any settings at this stage, merely try and troubleshoot and focus on where/when this issue is occurring.

    I do see a small arc when I probe the first pin of the connector with the white wires (5x)

    That shouldn't happen, that small connector is the power and logic supply to the inverter board.

    On the other side is the output to the CCFL - with the 2 wires, that is where I was referring to when you get an arc.


    If the fuse is showing no continuity, then it's possible the PWM transistors have failed.

    Just get standard 0.5AF glass fuse, break the glass, remove the wire and bridge the fuse on the inverter board and see what happens, it may just be a popped fuse.


    If it's the CCFL backlight that's burned out, these can be replaced but requires full disassembly of the TP and LCD screen assembly and therefore requires some good manual dexterity as well as keeping the LCD components super clean.


    I have replaced a CCFL in my time and just measured the diameter and length of the CCFL tube and got a stock one from a supplier that had the correct dimensions and got it working again, but took me that long, I've never attempted one again.


    So that may be an option if the CCFL is burned out.


    I would try and locate another one whilst you can.......I have a local source here in the UK that have plenty of these - 2nd user of course with cosmetic damages etc.

    If you want a contact, let me know and I'll send you it over via the 'conversation'.

    You would be best served using a silly scope (Oscilloscope) to look at the output not a DVM and you can get a 'little tickle' from it if you accidently touched the outputs with your fingers, so be careful around any inverter boards in general.


    I have noticed using some DVM's, if you just hold place one probe on the white/yellow wire, if it is functioning, you can see a small arc between probe tip and connection point.


    The 'pink' is generated from a small piezo inside the TP.

    Remove the back cover and power up - the 'pink' will be louder then.

    This will mean power is there and the TP is probably working and the controller powering up.

    You will also see more clearly at the bottom if the backlight is on or off.

    If you hear the 'pink' and no backlight, then could well be the inverter board at fault, or the backlight may have burned out AFAIK.

    I've managed to have a one on one discussion with a Kawasaki engineer regarding this and they can see the issue you've raised.


    From their perspective, the Kawasaki manual is correct as it details the recommended safety relay to be used to control the MC to disconnect the motor output, brake release, enable signals in the event of emergency.


    They cannot comment on the Mitsubishi document you reference to as this is produced outside of Kawasaki, but can appreciate your concerns and at this stage, can only confirm the Kawasaki recommendation outlined in the manual is an applicable design factor.


    They are going to contact Japan for clarity over this, but this may take sometime I'm afraid before a definitive answer is received.

    The spec sheets are golden to keep.


    In the event you ever have to reinitialize the controller:

    - this defaults everything to an empty robot and makes it unusable.

    - those spec sheets can return it to a shipping condition - ready to go out of the box.

    - if you make a file save, this could be used to load in after an initialization to return to it's last state.

    Good to have those, especially the firmware records..... :top:


    The Kawasaki Test Record always made me laugh.......I could never see the point of it as there were no real results in terms of value comparisons across 'x' amount of cycles.

    Just imagine receiving it, with a NOT OK in one of the judgment fields.

    The inverter board has a small SMD fuse 0.5A, if that blows then obviously no backlight, so that's worth ruling in or out, but I suspect it will be fine.


    cguenther has just had something similar happen to his teach pendant.

    Was working, then came to it and appeared dead.

    He thought it was something to do with it being very cold in his environment and left it warm up for a bit and hey presto, it came to life.


    Never heard of temperature as being an issue, but in his case it did the trick.

    Maybe worthwhile trying that out.

    PS: I have no idea what you mean by ex jaguar systems. They used to be in the jaguar factory ? I'm curious...

    PPS: My controller has yellow tape with "Halewood refurbished unit" on it, Maybe it rings a bell.

    Exactly.

    There is a Jaguar Automotive Plant at Halewood in Liverpool (UK) and in Solihull (UK), I used to visit there whilst I was employed at Kawasaki UK carrying out service and training tasks, so they are well known to me.


    They had a huge strip out of all Kawasaki C Controllers a few years ago and now they are appearing on the 2nd user market and several people (like yourself) who have acquired one visit the forum.

    Attached are the required documents which include:

    - Battery replacement.

    - Zeroing.


    Usually the encoder battery replacement procedure does not affect ANY zeroing if done correctly and before the battery is exhausted - that is a 5 minute job.


    If you are a Kawasaki client, you can sign up to the Kawasaki Download Centre where all manuals are freely available, follow the link below:

    Kawasaki Robotics Download Centre - Manuals, Software and Tools for Kawasaki Robots - Robotforum - Support and discussion community for industrial robots and cobots (robot-forum.com)

    Your TOOL variable name is too long (>15 characters) but wouldn't attribute to the error.


    SETCONDW1 and SETCONDW2 can be found in Aux 1401 Weld Conditions.


    Not 100% sure on your error during the load though, the error is pointing to the below explanation:



    What E controller is it and do you have up to date firmware loaded?

    Check out Aux 0804 and post the screenshot and I can check your current revisions?

    However I'm from Belgium.

    Heehee........each time an ex Jaguar (from the UK usually) C Controller appears on the forum, I always ask and they always appear to have departed the UK.


    Maybe I should think of moving to mainland Europe...... :hmmm:


    Thanks for the additional information, and yes if you don't hear the little 'beep', 'pink' sound then the TP is not receiving any power from the AVR via the 1HP board, XHP-CN4 to X1 harness, or X1 to TP or possibly the internal board.


    The supply is 12V+ and I know the AVR is providing that power, or else you wouldn't be able to energise the motors as the Servo board would produce an error.


    I would take apart the TP, back cover slides off after you remove all the screws and you'll be able to see the connector to the board.

    I would disconnect that and remove the complete harness.

    Completely stretch it out, then go down it feeling for kinks and cuts (very common intermittency).

    Then just bring the 2 connectors together (without curling the cable too much) and DVM measure them for continuity - using the information I sent you.

    I would also look inside the metal connector, it has been know for some of the pins to push in slightly when plugging it into the controller causing disconnection.


    If it is the internal board (1FT board is quite easy to replace), that maybe a pain to obtain as a separate item and you may just have to get a replacement complete unit from Ebay or something like that......may not be cheap though.

    I don't have a null modem cable on hand but I'll get one soon (usb variant is ok ?). I'll go fishing for a working laptop in the pile :D .

    You may have trouble with the RS232 route as ex Jaguar used to disable the programming port on the front and on the CPU board in the controller.

    RS232 programming cable can either be a null modem cable or simply a poor mans lead using 3 wires.

    2>3

    3>2

    5>5


    USB adapters are fine, but rarely cross over Tx and Rx lines, so either way you would need a null modem or poor mans lead if you go down the RS232 connection route and the port hasn't been disabled.


    Which leaves the Ethernet (from your image I can see the port just peeking out on the CPU board.

    But that means you would need a cross over ethernet cable (if going peer to peer), if going through a switch/router, then a patch lead would suffice.

    Also the problem of finding out the IP Address.


    If it is ex Jaguar, they used to print the IP Address to the teach pendant with yellow tape, so if that's present, that's the IP Address I would use to try out first.

    Never used any apps to sniff network traffic I'm afraid, but I think wire shark could be used to locate the IP Address.

    Eureka, Kawasaki has decided to publish the commands then.


    I have that same revision manual from a couple of years ago and no mention of host communications.

    I've just downloaded that revision again directly from the portal and they have been added now..... :mad:

    Kawasaki have not changed the revision number which they usually do 90210-1344DEB.


    Many thanks for posting this my friend, very useful indeed...... :top:

    Welcome to the forum...... :beerchug:

    Long time lurker and now getting your feet wet resurrecting a good old work horse......Love it.

    Looks like you've made some nice progress until the 'blank screen'.......shame, but all is not lost.


    Looks like an infamous ex Jaguar system to me.


    No VGA output signals from the controller, as the teach pendant is the VGA and just communicates to the controller via RX+,R-,TX+,TX- comms lines as well as the hard wired emergency stop, deadmans.


    Only way to get some comms is via RS232 to see boot up information, however most ex jaguar controllers had the RS232 port disabled as a default.


    So, we need to know:

    1. What is the Controller variant - Should have a rating plate on the controller probably C42.

    2. Usually on power up you get a 'small beep' or 'pink' from the teach pendant, do you hear anything.

    3. Turn off the lights in the room, check for the internal backlight - small strip of light at the bottom.

    4. Can you show a picture of the inside of the controller - Card rack file more importantly.

    5. Do you have any experience with using KCWin or KRTerm applications?

    6. Have a look here to download them and some connection instructions are included.

    Kawasaki Online Terminal Editors - Manuals, Software and Tools for Kawasaki Robots - Robotforum - Support and discussion community for industrial robots and cobots (robot-forum.com)


    If you can get online via a laptop using KCWin32, KCWinTCP or KRTerm, you will see the error produced, the fact you can still energise the motors and release the breaks proves there's nothing real fatal going on.


    So it should be limited to the teach pendant backlight tube, teach pendant inverter board (it has a small 0.5A fuse on it), teach pendant 1FT board failure, teach pendant harness (intermittent fault due to twisting, harness, X1 > XHP-CN4 (internal harness connecting teach pendant to 1HP board or CPU board (but I doubt it is the CPU).


    I would persevere with getting online first and determine what error is being produced and also obtaining a full file save whilst you can, so that you have a recent backup of it.


    If you are based in the UK, maybe I could give you a business visit for some assistance and training.. :top:

    Welcome to the forum........... :beerchug:

    Any suggestion how can I solve it?

    Cheers

    For sure, but there are plenty of questions first.


    Have you ever had ANY Kawasaki robot programming training?

    Why are you loading operation, system, aux, interface panel, signal name, storage data in?

    Where did you get the file from that you are trying to load in?

    Are you modifying a previous file save using a text editor and trying to load it in?

    What information are you specifically trying to load in?

    Looks good............. :top:


    Don't forget to ZROBOT it back to the correct model.

    Before battery change it was 29.0 now its 29.2. Which I'm assuming is just a timer and doesn't matter that much?

    Correct.

    The manuals say Error (-600) is "Motor power OFF. Displayed whenever an emergency

    stop is encountered" So this means my safety circuit is open?

    Correct.

    - You have 3 emergency stop circuits on the Kawasaki that run in series connection:

    - Operator panel, teach pendant, external emergency stop.

    - All 3 circuits need to be complete in order to allow motor power on.

    - You need to ensure the external emergency stop circuit is also configured.

    - Check your conversation for the external IO connection document - C80 references are in there.


    Please read the following and be clear and understand before you spend money on anything:

    - Kawasaki produced and supplied teach pendants with/without cables.

    - The part no. on the rear of ANY teach pendant, is the part no. of the teach pendant ONLY.

    - The part no. on the cable is the part no. relative to the connector/cable length ONLY.

    - If purchased together, a hybrid of the part no of the teach pendant AND cable was used.

    - When 'shopping', you need to make sure whoever is selling it can provide these details.

    - Just a picture of the teach pendant part no may not be correct, you need to see the connector.


    Type 1 and Type 2 teach pendants are designed to work with Cxx controllers.

    - The links I posted in #4 are of the Type 1 and Type 2 teach pendants, no others can be used.

    - C80 controllers are manufactured to take Type 2 with a square molex connector.

    - Other Cxx controllers were commonly supplied with Type 1 circular connectors.

    - Some C3x controllers were supplied with Type 2 and square connectors.

    - Type 1 teach pendant part no is usually 50817-122x

    - Type 2 teach pendant part no could be 50817-123x or 50817-126x.

    - The cables/connectors could be obtained with either a circular OR square connector.

    - C80 controllers therefore you should be looking ideally for a Type 2 with square connector.


    Type 1 and Type 2 teach pendants were available with either circular OR square connectors.

    - I have never seen an adaptor to convert circular>square or square>circular.

    - Logic tells me, as they could be supplied with either connector, an adapter could be made.

    - cguenther has a type 1 circular connector and is in process of making a circular>square adapter.

    (check your conversation for the wiring of C80 and C70 teach pendant signals inc emergency stop).


    Warning:

    Commands sent from KCWin, can cause FULL speed motions of the robot.

    This is very risky unless you are competent with such commands and have a safe and correct emergency stop circuit accessible and a robot sufficiently mounted with clear space to move.


    Personally, if I was you I would:

    - Check and configure your external emergency stop and teach pendant emergency stop.

    - Appreciate that you have no teach pendant and emergency stop button available.

    - Wait for cguenther to see if he is successful or not before buying a type 1 teach pendant.

    - Or try and locate a type 2 teach pendant with a square connector so you have a correct system.


    Now for you and cguenther

    - A local source of mine in the UK appears to have some 50817-1260 Type 2 pendants available.

    - I am waiting for them to confirm if they have circular or square connectors.

    - They cannot guarantee if they work or not as they don't have any controllers to test them on.

    - Therefore they can only supply these as untested and no prices have been discussed.

    - Hopefully I will get further news on this next week.


    Dependent on the results, if either of you would be interested, I will pass over their details to you, so that you can deal with them directly and negotiate whatever deal you can with them.

    So what is the controller you are using?


    Latest controllers have 2 ethernet ports which can be used for TCPIP protocols.


    The 2nd ethernet port can be used for software ethernet/ip, if this is used then that ethernet port cannot be used for anything else, but may require enabling as it is optional AFAIK.

    However, you can only send integer values across.


    Where as with TCPIP, you are not restricted in that respect as they are string messages, so that would be more flexible IMHO.


    All depends on what protocols are available on the Keyence then.