Hello everyone.
Just noticed that my last post was approx a month ago and there has been so much improvement and communication between kwakisaki and kawasaki germany behind the scenes that we decided not to chit-chat everything in this main thread but to conclude the highlights and howtos on an ongoing way.
First of all: The Robot is moving, the motors are working.
What was the way to this milestone:
On the last post, we were stuck at this nasty error-code 1420. As i did all the flashing of the card on my C70-controller und putting them again into the C80 for testing, we decided to rule out possible root-causes of the problem: First of all, i got my hands on a New-Old-Stock 1HA-Board, 50999-0020, what initially was rumored to be a successor of the most desired 50999-2384, Ethernet, 4MB, Mainboard. This was meanwhile confirmed by Kawasaki Germany, that the the 50999-0020 can be seen as a full replacement of this 2384.
Next thing was hook-up a Tech-Pendant (or MFD: Multi-Function-Display, Multifunktionsdisplay in German) on the C80, because the original one was missing. We had some hints in the Manuals, that there was the possibility to have a Type-1 on the C80, however, standard would be the larger, white, Type-2 variant.
However, the phisical connectors are quite different between my C70-Type-1 and C80-Type-2:
Connector on C70 Controller for Type-1 TP:
Connector on C80-Controller for Type-2-Teach-Pendant:
Looking into the wiring, all is straightforward, except another pinning for the EmerSwitch and some other layout of the two trigger-switch-circuits.
The C80 "expects" to have two seperate Circuits for each trigger-switch, whereas the Type-1/C70 has two Trigger-Switches as well but the are pinned out "or", what means if the left or the right button is pressed, the circuit is closed. On the C70-side, there are two inputs as on the C80, but one input is already bridged by factory.
So i wired the Adapter accordingly - and it works.... not directly.
First problem was, after a quick test, the TP seemed to be dead suddenly, but it turned out, that ambient temperatures of below 5deg C/40deg F will stop the TP working (or at least lighting up the CCFL, didnt testet it).
Second, i managed initially NOT to have continuity in my Trigger-Switch-Bridge as described above, what pops a "inconsistent"-state error.
After all of this was fixed - voila. The TP initially complains about a Software Mismatch, so it was flashed to the original TP-Firmware the Robot was delivered from the factory (what was/is for a type-2 TP, but it works) what was supplied by Kawasaki Germany on request (Thanks again!).
Thereafter AS and SV-Firmware was flashed to the original states, factory like, and.....
1420-error again!
So, finally, this error was solved by going through the factory-sheet and configuring the C80 as it should. What was finally exactly solving the error is unknown, but there were a couple of inputs needed, which were incorrect after the full-reset (motion-mode, servo-mode, controller-type e.g.)
Actually the current status is:
- Floppy needs to be enabled/checked
- Motors/Joints only turn in one direction - even it turned in one direction, not able to turn opposite.
- Arm is lying on its side, will be mounted during the next days.
Will keep you updated!
Like before, a big shoutout to kwakisaki, who was&is a supporter und motivator to try&do and bring things forward. thanks a lot!