Hi kwakisaki,
Thanks for your comments. Before get it back running again I got only one error with the Check sum which could the reset in the settings.
You can solve "Check sum error" follow next steps.
AUX 0803 (Menu -> System -> Sum Check Error Reset)
Check box move to Off.
and Press "ESC" button twice on T/P.
your E0903 error message will be clear.
but, When a Cold start (Turn off -> Turn On) system, that parameter will be automatically returning to On.
OK....1 last confirmation.
Racermike123, in another thread you posted "The only rule for mastering a Fanuc is that axis 2 must be at zero to master axis 3 at zero."
If I do single axis mastering as mentioned above, does this not apply? My plate would not have axis 2 and 3 @ 0 degrees. I will know the positions of 2 and 3, but they just won't be zero.
Thanx again!!! (and again, and again. I want to change how we do things here but the guy "in charge" (who isn't involved with the mastering after a wiring harness job) is quite stubborn, and I HAVE to have this right before I bring it to management. He thinks quick master is the best way to go....we always have problems when we do that)
Axis 1, 2, 3 possible single mastering
but Axis 4~6 must have to same zero angle and execute mastering.
becuz related reduction gear and pulse code refer each axis 4 ~6
OMG... I'm so sorry.
I'm assuming use IRC5 controller type...
may the force with you !
Almost robot maker support "Palletize" option.
Very useful and easy. but I don't like.
Because it will disturb "Understand of 3D layer from Program Logic".
I think to understand of palletizing, create only programming.
FANUC, ABB, KAWASAKI as the same logic process.
Calculate number by Divide, Module.
and define Row, Column, Layer
mix Offset value
execute Position mix with RCL value * Offset Value
so, you don't have worry without palletize option.
The main point is all robot possible without palletize option and can create only basic program (instruction)
becuz Manipulator and Controller's information data as synchronized.
(Robot Model, Robot Option, Robot Serial Number, Encoder Value etc...)
when you swap another MH5 robot, T/P will be display error messages.
so, if you wanna swap another Manipulator, Install and Initialize Manipulator.
this case as same another maker robot products.
1. manual check motion with STEP On condition.
2. When MOTN-018 appear again with STEP off condition, maybe calculate next position out of actual Stroke. becuz robot Precedence calculate next Motion data.
MOTN-018 is meaning out of stroke. Not undefined position data.
so, you have to check XYZWPR value.
1. Cable Harness connect before turn off main-power source.
2. External_Axis install at correct place before test Motion (jogging) finish step.
3. This EXCEL file refer MU400 External_Axis Model.
4. And you have to Load MU400 motor cfg files. (check attach file)
(RobotStudio - Controller - Load Parameters - Load parameters if no Duplicates)
I dunno how calculate PCD from Motor's rev/min or Gear pitch or ....
so, final tune via "Tune Master" application from ABB official site.
a. Turn off and Install all harness.
b. Turn on and Load MU400 cfg file.
c. Warm (or cold) reboot
d. Calibrate (Zeroing) M7DM1 from Calib menu.
e. instruction use ActUnit M7DM1;
f. Manual Jogging Test
g. Turn off and External_Axis install at correct place.
i. install or assembly other mech unit for external axis
j. Turn on and jog test (Jam or Smooth)
and... need backup before this progress. OK?
i - All connector or Cable name are may not match your environment.
Are you try to Restore?
in Controlled Start window (when finish init start, automatically into ctrl start window)
Press "MENU" button and select "System Variables"
next, F4(Restore)
follow displayed request.
nCount := 0;
pStack := pWork_Origin;
nOffs_X := 200;
nOffs_Y := 50;
nOffs_Z := 300;
nRow_X := Abs(nCount DIV 3)
nCol_Y := Abs(nCount MOD 3)
nLay_Z := Abs(nCount DIV 6)
pStack := Offs(pStack, nOffs_X * nOffs_Y, nOffs_Y * nCol_Y, nOffs_Z * nLay_Z);
MoveJ Offs(pStack, 0, 0, 300), v1500, z50, tool0;
MoveL Offs(pStack, 0, 0, 50), v500, z10, tool0;
MoveL pStack, v300, fine, tool0;
rGrip_Open;
nCount := nCount + 1;
MoveL Offs(pStack, 0, 0, 50), v500, z10, tool0;
MoveL Offs(pStack, 0, 0, 300), v1500, z50, tool0;
I've heard ABB and Ford co'op Development IFWC (Integrated framework Controls).
anyone experience this system?
ah, now project from FORD and we will delivery to South africa 
1. Turn off Power
2. Open E_Controller Upper Cover Plate
3. Find Dip_Switch (Blue square and white color). this switch near RS-232C port.
4. You can find all dip_switch set "Off" status.
5. Only No.8 Dip_Switch set to "ON"
6. Turn on Power
and T/P will be display wait user command for Initialize.
Initialize ?
0 : No
1 : System Initialize
2 : Factory Setting
Dip_Switch No.8 must be set "Off" before Next cold or warm reboot.
ah... still your T/P freeze status....
1. Turn off Power, Remove CF Memory card and Re-Install, Turn On
2. Replace another T/P unit.
3... Call Kawasaki A/S Team 
...
Not exist easy way for teach.
U should better explain your process or Layout.
Teach before need understand Concept.
Concept from Interface, Tool, Layout.
um... Can you explain your program ?
I can't guess your problem's main point 
Ok, anyway you cannot control Motor_On via push Button right?
can you discribe Error logs?
Service - 7. System Diagnosis - 2. Error Log
(E0102)Variable is not defined.
(E1119)Command value for Jt3 beyond motion range.
(E1123)Speed error jt 2.
(E6502)Arc failure.
(E6506)Torch interference.
(E1128)Uncoincidence error betwen destination and current jt 4 pos.
(E1192)(SSCNET) Deviation error of Jt 13.(code 52)
(E1192)(SSCNET) Deviation error of Jt 11.(code 52)
(E1030)Encoder data is abnormal.( jt 11 12 13)
(D1535)(SSCNET) Alarm of Jt 11.(code 35)
(E1363)[Servo board1]Speed of flange center point exceeded safety speed.
oh... too much Errors
E0102 is unable refer not initialize values.
or Not defined data name.
E1119 is When u use SHIFT or Decompose or TDraw ... alike something
replace current position will be display out of Robot's Stroke.
E1123
Reason
a. Motor Power cable U, V, W disconnect or Arm falling via Power_Block badness.
b. Motor Power cable or Encoder Harness badness.
c. Encoder harness disconnect or Encoder Unit badness.
d. Suddenly Singularity moving happened.
e. Servo Board fault
f. Install too much Payload tool or Inertia above motor's torque when drive 100%
Solution
a. Check harness cable
b. Replace servo amp unit
c. Replace encoder
Actually, robot's all postion from Sevro motors Encoder Value(HEX)
- Guess 1 -
Ah.. is that Step instruction include R(Shift) ?
When calculated data out of robot's stroke, Some error popup message showing.
- Guess 2 -
Step Motion type P(Joint) and L(Linear) .....
When nearst Singularity (Joint 4,5,6 Flat figure) motion...
You can solve use Motion with P.
Hmm... is that controller connected "Safety wire"?
Common control for...
Emergency Stop
External Hold
Motor Off
Motor on
So, make sure "Relay" 24v status.
Robot need Closed(B) contact.
If didn't connect safety wire,
Try Press and release Green Round button on T/P
and keep deadman switch.
Basic is very simple.
PROC rCycleTime()
VAR clock clock1;
VAR num nCTime;
ClkReset clock1;
ClkStart clock1;
ClkStop clock1;
nCTime := ClkRead(clock1);
Return
EndPROC
Assign that VAR type data into Mainmodule or UserModule.
Clk RESRT, START, STOP, READ is unique instruction.
So, insert ClkReset and ClkStart instruction into main procedure.
When progress reach Retun before insert ClkStop and Apply Number data from ClkRead
clock, nCTime - Not assign naming format.
But keep type "clock" and "num"
- Record Type -
Every position(Step) contain Cartesian or Joint angles.
(Except ie - Global & Local P*** data.)
So, You can change position type in "Quick Open"menu.
I think should better use Cartesian(XYZ,rXrYrZ).
Because readability better than Joint angles.
- One position(Step) mix Different Options? -
The answer is No.
but you can use refer below instruction.
S1 MOVE L,P1,S=30%,A=3,T=0
S2 MOVE L,P1,S=30%,A=3,T=2
When you Record Global Position Number 1 and define Tool data at No.2, robot wiil be reach different position.
P1 is absolute Position.But S2 instruction define Move by Other Tool_Frame
