Good components on spare board
Put all the Kawasaki's, Controllers, Arms, Cables and Pendants in a crate and ship them to the UK
I found where the smoke came from
Thanks Kwaki, I will give these a bash and see what happens. We were looking at replacing these robots next year in any event, so the boss must decide if we repair...
That's definitely not a good sign.
Did you carry out any voltage checks and brake release button checks before like I suggested?
Yes I did, all were normal/consistent, except for the brake release which was still not working on all joints (1-7)
Ok, so error D1513 has reappeared, (there was a puff of smoke in the controller) ; F4 did not trip but I can't clear the error at all now. All I did was switch on the motor and pull in the dead man switch. I suggested that the boss get ahold of the agents here to come and sort it out.... Can't see anything burnt in the controller.
I had an error D1513 on the same robot that you helped me fit a servo motor to a radial arm drill (January 2020 Controller D42F-A001 a ZX165U robot)
I have looked through your replies on the thread June 24th 2019, and eliminated most of the things you suggest.
None of the brake releases work (1-7), F4 was tripped but it is on now clear and I am sitting with another error (D1512) on all joints (1 to7). I have swopped boards, checked cables, swopped cables and the error persists. There is a small piggy back board (1KV-50) that looks like it may have taken a knock (see 1KV-50 pic) - there was a power surge here that affected 2 of our laser cutters as well. Any further ideas?
Hey bud, it's taken a while, but I finally got onto this robot this morning.
All went well, I kept the spare robot and controller together and went through the motions you supplied. The ARMID error came up initially, but after I reset it, it did not ask for it to be changed again. Re-zero of joints was ok as well, had to do Encoder Counter Rotation Reset for all Joints. I also sorted the connections on the 1KP board X7 and X8 as recommended. Ready to go to the next step of adding the external axis, I will PM you a backup of the robot as it now stands
[quote]3. Reinitialize and return firmware to handling.
- Load in a backup from your production robot (cloning it basically with all the IO, dedicated signals and system settings).
- Do a 'user' initialization (which removes existing user data such as programs/variables etc).
- Change the serial no. and add additional axis and configure it in software (you should have the existing electrical connections already made).
- Extract the servo parameters from your old backup and load them in.
- Connect the JT7 motor (clamp it down) and do some initial setup and configuration to get it moving accurately and smoothly.
- Load in the programs from your production robot and incorporate the drill motor addition.
After discussion with my boss and the owner, we are going to decide on option 3.
I have a jig to build, so will be busy for a while, but my boss has agreed that he will set aside some dedicated time so that I can
fully concentrate and apply myself to getting this robot set up and running. Thanks for your guidance and suggestions, always
Great pictures by the way...…….
Looking a little closer, I can see it's a CC Link (1HS Board).
Also, the supply for the servo gun picture, is the weld timer (I think).
What I can supply is (will take me a couple of days to get together):
1. AS and SV firmware to return it to a standard handling robot.
2. A 'dummy' file from KROSET (Simulation) to load in with standard handling settings for the ZX165.
I would advise to remove the 1HS board, move IO board at OPT3 to OPT1 (where the 1HS board used to be) and remove the IO board in OPT4 as this would return it to a 'standard' handling controller from a hardware perspective.
The removed boards could be re-added later on if required.
I think it's doable to return it to handling and you may need to remove any additional services attached to the arm, as they wouldn't be required......except for the 'black box' I was referring to (I'm sure it has one).
Sorry in the delay, only getting back onto this now (work happens... )
I have done as you suggested above, my boss wants to keep the (spare) replacement robot with its own controller, simply so that we can get it working in our workshop, bring in the spare Drill Press, and set up the servo feed before we interfere with the (current) production robot.
Now that I have returned the spare robot to a handling robot (from a hardware perspective), do I just initialise it and go through the setup? Or do I still need the AS and SV firmware you mentioned, and a dummy file from KROSET?
You are correct.
We want to take the old robot out and replace it with the one that was in storage. Then, we will link in the servo control motor to the feed on the spindle to control the feed rate and improve cycle time. We do not want to use the spot gun at all. The old robot is giving problems with communication on one of the motors, so instead of replacing encoder or motor or harness (could be any of these) and re-programming, we want to put the newer robot in and upgrade the cell at the same time.
Thank you Kwakisaki, your help is most appreciated. I have attached pictures of the following:
1) Arm Id board
2) Our current Material handling robot with pedestal drill.
3) Servo motor from spot gun arm
We want to use the servo motor in the attached pics to control the quill feed. Currently it is just an auto engaged feed with sensor feedback that wastes a lot of time until it actually gets to the pipes it is drilling. I would then need to use the supplied Aux block to control this motor. I would imagine that I would then change cards differently to what you have suggested, but we can still remove the external axis control board(s)? Please have a look and let me know if I need to clarify anything for you...
- This I can provide you some pointers with to assist you if required
Please do, as I said, I know Yaskawa setup quite well but have only been working with Kawasaki for about a week
No luck, the error persists. I am also tending towards a re-initialize. Attached see pics and backup files (MHR03 is the very 1st backup, AUX6012 is after your suggestion) You can see the expansion block you mentioned, maybe they put 1 inside and the other 2 externally?
Although I have not seen the additional cabinet you have attached, I strongly suspect that this was the case, as it has both joint 7 (gun) and joints 8 & 9 (manipulator, or turn/tilt). My employer bought this robot quite a few years ago and has had it in storage, this is only my second week here. I am currently busy changing all the signals in AUX 0601 and AUX 0602. Just happy that it looks like I am on the right track. I will let you know what happens
My company bought a second hand Kawasaki handling robot that was doing spot welding in Australia. It had a spot welding gun (which we have taken off - we will put a gripper on it for handling piping)and had an external axis attached as well.
When we start up the robot, it comes up with the following error:(D2008) Magnet is Contactor of group1 is stuck.
I cannot clear this (Major alarm) and I am not sure what group1 is. Is it perhaps in the controller or maybe it was the spot welding control cabinet and it is waiting for an ok return signal?
Sorry if this is a stupid question, I have worked with Yaskawa for a few years but this is my first experience with Kawasaki robots.
We do not have access through the PC card, can we input this through the teach pendent? On our backup, I can see it is on, but maybe it was re-set to off when we re-initialized?
Thanks for your reply. Yes, the FDD unit was previously working, we have made a backup and then we re-initialized the robot controller. It is a D controller (Model D42F-A001) Jap Spec. I will post file save to check if function is enabled as soon as I can, I have a feeling it is not enabled. I have worked with Yaskawa robots for about 12 years, it is my first experience with Kawasaki, so I am still learning how it works. Do you perhaps know how to enable the FDD function?
The controller does not see the FDD, only the PC. How do I tell it that the FDD is there so that it can load data to the robot controller (Backup)