Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT MPVDCONTV113E-3 Kawasak Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and is furnished solely for customer use only. No other uses are authorized or permitted without the express written permission of Kawasaki Robotics (USA), Inc. The contents of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical, electrical, photocopy, facsimile, or electronic data media, without the express written permission of Kawasaki Robotics (USA), Inc. All Rights Reserved.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REVISION HISTORY Revision Number Release Date Description of Change Initials -0 11/20/03 Initial PDF release, based on Rev.-0 of print copy CB/CB -1 4/27/04 Revision 1, based on Rev.-1 of print copy CB/CB -3 9/06/05 Revision 3, based on Rev.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.0 1.1 1.2 1.2.1 1.2.1.1 1.2.1.2 1.2.1.3 1.2.1.4 1.3 1.3.1 1.3.2 1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.4 TROUBLESHOOTING ................................................................................... 1-2 Error Recovery ............................................................................................... 1-2 Preliminary Troubleshooting .........................................................................
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.0 TROUBLESHOOTING This unit provides error recovery flowcharts, error code information, and error code troubleshooting flow charts. In addition, typical causes and remedies for the errors are also provided. 1.1 ERROR RECOVERY Figures 1-1 and 1-2 show troubleshooting processes that may be helpful if the controller becomes unresponsive to commands or an error code has been encountered that cannot be cleared.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Locate error on the error Source of error known table and determine the characteristics and possible causes of the error Troubleshoot and correct source of error Run Program and continue to monitor Source of error unknown Error cleared and robot runs normally Press the yellow reset button on the controller panel Run Program and continue to monitor Error will not clear or machine is in a “locked” mode Have any cha
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING Continued from previous pg Error still present Remove the 1KA board from the rack and allow RAM memory to deplete Reinstall 1KA board, initialize the system, zero Error clears and robot runs normally Run program and continue to monitor Begin electrical troubleshooting and repair if qualified; call service technician for further assistance Figure 1-2 Troubleshooting Process (Continued) 1-4 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.2 PRELIMINARY TROUBLESHOOTING Prior to following error code troubleshooting procedures, ensure preliminary troubleshooting steps are completed. 1. Ensure proper 460 VAC three-phase power is available at the input and output side of the controller main disconnect (circuit breaker F1). 2. Ensure circuit breakers F2, F3, F4, and F5 are not tripped. 3.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.2.1.1 CONTROLLER POWER CANNOT BE SET TO ON This failure occurs when the controller does not power-up when the controller main disconnect is set to ON. Failure 1: When the controller main disconnect is set to ON, circuit breaker F1 is tripped immediately. Main causes include: 1. The AC power line is short-circuited in the controller, and circuit breaker F1 detects overcurrent and is tripped. 2.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ⇒ Ensure primary power supply is within specifications. Ensure primary power supply cable is properly connected and is not damaged. ⇒ Ensure connectors at the 1KQ/1NR board are properly installed and not damaged. ⇒ Ensure the 1KP board fuses F1 and F2 are not open. ⇒ Replace the 1KQ/1NR board. ⇒ Ensure the power supplied to the AVR power supply is within specifications.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.2.1.2 TEACH PENDANT IS INOPERABLE The teach pendant is in operable with the controller main disconnect set to ON and the control power lamp is illuminated. Failure 1: The control power lamp is illuminated and the teach pendant is inoperable (the back light is not illuminated). DC power is supplied to the controller, but power is not supplied to the teach pendant to illuminate the display or back light.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1KX/1NX Mother Board Display Device Input Keys 1KA Main CPU Board Teach Pendant Figure 1-3 1KA/Teach Pendant Communication Main causes include: 1. Interruption in data communication between the teach pendant and the 1KA board. 2. Defective LCD panel, circuit board, or other internal teach pendant components. 3. Defective 1KA or 1KX/1NX boards. 4. Disconnected or short-circuited teach pendant cable.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING 1.2.1.3 MOTOR POWER CANNOT BE ENABLED This condition exists when motor power does not engage when the MOTOR POWER switch is pressed. Main causes include: 1. An error condition exists. 2. K1, K2, or K3 are not engaged due to a defective 1KQ/1NR board, MC unit, teach pendant, software, eternal signals etc. 3. Emergency stop condition exists. 4. Defective power block. 5.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.2.1.4 ROBOT DOES NOT MOVE This condition exists when the robot does not move when conditions are set for teach or repeat mode. Main causes include: 1. External hold condition exists. 2. An error condition exists. 3. Operation panel switches set incorrectly. 4. Motor brakes are not released. 5. If the check mode is selected, ensure an enabling device is engaged and the GO (step forward) key is pressed. 6.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING 1.3 ERROR CODES This unit provides information about the error codes that are displayed on the teach pendant or other user interfaces that provide display screen information. The error codes are listed in numerical order by prefix and code number with the message that is displayed on the teach pendant. An expanded explanation of the message is provided along with possible methods to clear or prevent the specific error.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.3.1 ERROR DISPLAY Error messages are displayed on the teach pendant LCD screen and/or a PC interfaced with the controller using KRterm/KCWIN32 terminal software. The teach pendant LCD screen displays operation errors (P errors) in the system message area and other error messages are shown in a pop-up screen display (Figure 1-4). Program pg6 [ Step [Comment ] ] [ 1 ] Status PC 1 pcprg1 T Program aborted.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING 1.3.2.1 DXXXX FATAL ERROR CODES ERROR CODE D0001 CPU Error. (PC=XX) The 1KA board CPU has stopped (detected by the AS software). This error is caused by defective AS or servo software, defective hardware, or noise related malfunction.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D0003 VME BUS error. (PC=XX) This error occurs when the CPU does not receive a response from one of the I/O bus devices within a specific time. This error is caused by defective AS software, defective 1KA board, or noise related malfunction.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D0005 [ARM CONTROL BOARD] CPU BUS error. (PC=XX) On the 1KB board, a bus error occurs (in the VME bus line, detected by AS software); data processing is not completed normally. This error is caused by defective AS software, defective 1KB board, or noise related malfunction.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D0901 AS Flash memory sum check error. A check sum error occurrs in AS software, in flash memory on the 1KA board, when the controller is powered-up. The check sum data is created when the FCHK command is executed and is recorded in flash memory during AS software download. Main causes include: 1. When the AS software is downloaded, the FCHK command is not executed. 2.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D0904 Memory is locked due to AC_FAIL. The memory is accessed during the controller shut down due to a power supply abnormality (ACFAIL) (AVR +5 V, +12 V, -12 V, +24 V). ⇒ Cycle the controller power OFF and ON. ⇒ Check for proper AVR voltage supply (+5 V, +12 V, -12 V, +24 V) and related circuitry.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1002 Init. error of servo software. Servo software (armsc.mb) initialization failure at controller power-up. Main causes include: 1. Servo software is not installed correctly or is corrupt. 2. Incompatibility between the AS and servo software. 3. Defective 1KA and or 1KB board. ⇒ Reinstall servo software. ⇒ Check compatibility of AS and servo software and reinstall software as needed.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1004 [ARM CTRL BOARD] watch dog error of servo control software. The watch dog circuit on the 1KA board or 1KB board has detected a software problem. This is caused by a defective 1KA main CPU board or 1KB servo CPU board or a problem with the servo software.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1006 AMP power unit error. General servo system error. This error indicates that a servo system error has occurred. Refer to any other servo system errors which occurred at the same time. When a servo error signal (SVER) is sent from the 1KB board (servo CPU board) to the 1KP board (power sequence board) motor power is shut down. The error notification is sent to the AS software via the EPLD.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1007 Regenerative time over [XX]. This error occurs when current is sent to regenerative resistors for six or more consecutive seconds. When the robot decelerates, the motors enter the power generation state to absorb the inertia energy from the arm. When the P-N power voltage exceeds the rated value (390 VDC), the current is split from the power block to the regenerative resistor.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1008 P-N low voltage [XX]. The voltage between P-N supplied to the power block is 60 VDC or less at servo on. ! WARNING Because motor power is not supplied, when low voltage occurs, the arm will fall until the error is detected. As a result, other errors may be generated (abnormal speed, deviation error, etc.).
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1009 P-N- high voltage [XX]. The voltage between P-N supplied to the power block exceeded 410 VDC.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1010 Regenerative resistor over-heat [XX]. The thermal switch for the power block regenerative resistor unit, or the optional regenerative resistor unit reached 140° C (284°F), or the heat sink thermal switch reached 90° C (194°F), or the controller cabinet thermal switch reached 70° C (158° F).
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ⇒ Reteach program steps to eliminate sudden high speed direction changes (dynamic shock). ⇒ Ensure cooling fans are in proper working condition. ⇒ Reduce controller ambient temperature. ⇒ Replace defective thermal switch(es). ⇒ Repair or replace disconnected or defective harness(es). ⇒ Replace the regenerative unit. ⇒ Replace the 1KB board, power block or harness. ⇒ Replace the additional regenerative resistor unit.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1013 P-N capacitor is not discharged. This error occurs when motor power is OFF for a period of time and the P-N power voltage does not decrease to 60 VDC or less.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1016 Data applicable to the robot model not in servo servo data file. This error occurs when the installed robot model file is not found in the servo data file. ⇒ Contact KRI customer service (include operating conditions/settings at the time the error occurred). _____________________________________________________________________ ERROR CODE D1017 Error of download of servo data.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1500 Encoder misread error JtXX. Immediately after control power on, steady encoder data is not able to be read. This error is caused by a disconnected encoder signal line or a short circuit, or a defect in the main body of the encoder. Encoder Encoder Encoder I/F Power circuit Battery 1KB board 1FG/1HG board Encoder power supply +12 V Controller Robot Main causes include: 1.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1501 Defective gun changer connection or encoder comm. error. This error occurs when the servo weld gun is connected and encoder data is not read normally within the specified time. Main causes include: 1. Improper connection at the tool changer. 2. Defective encoder or encoder communication line. ⇒ Check tool changer connection and repair as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1503 Current detector type (XX) mismatch! When the control power supply is turned ON, the ID code data of the 1GM (1KV) board and the AS software installed on the 1KB board do not correspond. The unit name of the servo board displayed at (XX) in the error message corresponds to the CH column in the table below.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1504 Abn. curr. feedback Jt XX. (Amp fail, pwr harness disconnect). This error occurs if the current feedback value is near 0 from the time the servo is turned ON until the brake is released, even if the commanded current value meets or exceeds the expected current.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1505 Motor harness disconnected or over heat. (XX) Motor thermal circuit is open due to motor overheat or harness problem. Not all robot models utilize thermal switches in the motors. Some robot models may have multiple thermal switches connected in series (see diagram below). The FS03/06/10/20 robot models have the thermal switch mounted near JT1 motor.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1506 Power module error JtXX. An error signal from the IPM module in the power block is detected by the 1KB board. Motor Robot Interface CPU PWM signal Servo CPU IPM error signal IPM HIC Gate Array Power block 1KB board Controller Main causes include: 1. U, V, and W phase short-circuited or short-circuited to ground wire. 2. Payload weight exceeds rating. 3.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1507 AC primary power OFF. This error occurs when there is an instantaneous decrease in the primary power to the AVR for control power supply (130–145 VAC or less for 20–30 msec).
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1508 24VDC power source is too low. 24 VDC to the power sequence board has dropped to +21.6 VDC or less. Primary power F1 Control power 210 VAC Circuit breaker Main disconnect T1 F3 AVR for control power Transformer 1KQ/1NQ board 24 VDC monitor EPLD Mother Board 1KX board Local bus DC error signal 1KP board 1KB board Main causes include: 1. Defective AVR for control power supply. 2.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1509 Primary power source is too high. Voltage level of the AVR for the control power supply is too high (267-277 VAC or more for 1-2 sec.). Primary power F1 Control power 210 VAC Circuit breaker Main disconnect T1 AVR for control power AC error signal F3 Transformer REMOTE 1KQ/1NQ board AVR output cut EPLD Mother Board Local bus 1KP board 1KX board Main causes include: 1.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1510 Primary power source is too low. Voltage level of the AVR primary power supply is too low (150-158 VAC or less for 1-2 sec.). Primary power F1 Control power 210 VAC Circuit breaker Main disconnect T1 F3 Transformer 1KQ/1NQ board AVR for control power AC error signal EPLD Mother Board 1KX board Local bus 1KP board 1KB board Main causes include: 1.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1511 +12VDC or -12VDC is abnormal. +/-12 VDC supplied to the 1KA board is out of specifications. +12 VDC: +10.75 VDC or less. -12 VDC: -10.4 VDC or more. Main causes include: 1. Defective AVR. 2. Defective 1KA, 1KB, or 1KP board. 3. Power supply contacts in the motherboard are damaged. 5. Defective power block. 6. Defective 1FG/1HG board. 7. Short in the harness between the servo unit and the 1FG board. 8.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1512 Brake line error for JtXX. This error occurs when the 1KB board detects an error signal sent from the brake release control MOSFET on the 1KQ/1NR board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING necessary. ⇒ Check and repair brake power line and connections as necessary. ⇒ Check and repair connections between 1KB and 1KQ/1NR, 1KB and 1KX/1NX, and 1NR and 1NX as necessary. ⇒ Ensure the 1KB board is properly seated in the card rack. ⇒ Ensure the 1KP board safety circuit setting is correct. ⇒ Replace the 1KB and or the 1KQ/1NR.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1514 I/O 24V fuse is open. Fuse F2 on the 1KP board is open. Main causes include: 1. Solenoid valve or diode polarity reversed. 2. Current load on the 24 VDC I/O circuit exceeds rating. 3. Short-circuit or ground fault in the 24 VDC I/O harness. 4. Defective 1KP board. ⇒ Check components for proper polarity and repair as necessary. ⇒ Ensure the load on the 24 VDC I/O circuit is within rating.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1517 Blown fuse on safety circuit emergency line. Fuse F1 on the 1KP board is open. Main causes include: 1. Incorrect wiring in the emergency line (wiring harness, emergency stop, safety fence, external trigger, teach pendant, limit switches). 2. Short-circuit in the emergency line (wiring harness, emergency stop, safety fence, external trigger, teach pendant, limit switches). 3. Defective 1KP board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1519 Mismatch of the safety circuit LS condition. In a double safety circuit system, conditions set for contacts in the limit switch (LS) circuit do not match. Main causes include: 1. Defective harness connection or harness (short-circuit or ground fault in harness). 2. Defective LS override switch. 3. Defective 1KP board ⇒ Replace the controller/separate/machine harness(es).
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1522 Mismatch in cond. of safety circuit enabling device. In a double safety circuit system, conditions set for contacts at the TRIGGER switch circuit do not match. NOTE If the trigger switch is not pressed firmly, only one contact may engage resulting in this error. The trigger switch has three positions and pressing too firmly may disengage the trigger circuit.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE D1525 Incorrect operation of MC (K1). Main causes include: 1. Defective controller harness. 2. Defective magnetic contactor K1. 3. Defective MC unit (1KQ/1NQ board). 4. Defective 1KP board. ⇒ Replace controller harness. ⇒ Replace magnetic contactor K1. ⇒ Replace MC unit (1KQ/1NQ board). ⇒ Replace 1KP board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1528 Controller temperature is out of range. Temperature inside the controller exceeds specification. Main causes include: 1. Defective cooling fan(s). For D7X controller, defective heat exchange fan on the left side of the controller. 2. Ambient temperature above specified rating. 3. Defective 1KP board. ⇒ Inspect cooling fans for proper operation and replace fans and/or fan harness(es) as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D1531 Heat sink on power block overheated. Main causes include: 1. Temperature inside the controller above specification because of air inlet or outlet blockage. 2. Defective cooling fan. 3. Defective power block. ⇒ Ensure air inlet and outlet ports are clear. ⇒ Ensure cooling fans are in proper working order. ⇒ Replace the power block.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2002 No response from the arm ID board. Main causes include. 1. Defective 1KB board. 2. Defective 1KP board. 3. Defective 1GV arm ID board. 4. Defective harness. 5. Noise related malfunction. ⇒ Replace 1KB board. ⇒ Replace 1KP board. ⇒ Replace 1GV board. ⇒ Replace harness. ⇒ Check for noise malfunction and shield integrity.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2006 Communication board to explosion-proof teach pendant watch-dog error. This error occurs when the CPU on the communication board (1GS board) for the explosion-proof teach pendant is suspended. Main causes include: 1. Defective communication board (1GS board). 2. Defective main CPU board (1KA board). ⇒ Replace defective 1GS board. ⇒ Replace defective 1KA board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2011 Parameter download error between user I/F & arm ctrl boards. 1KA and 1KB boards parameter exchange cannot be downloaded. ⇒ Replace the 1KA board. ⇒ Replace the 1KB board. _____________________________________________________________________ ERROR CODE D2012 SOFT ABSORBER error. Turn OFF & ON the control power. (Software absorber function) Main causes include: 1.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2016 No response from the arm control board. Request is sent to the 1KB board from the 1KA board and there is no response. ⇒ Reset error and if error recurs, replace the 1KA/1KB boards. _____________________________________________________________________ ERROR CODE D2017 No response from User I/F board. 1KA board software stopped. Main causes include: 1.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2020 [ARM CTRL BOARD] servo control software no response. 1KB board software stopped. Main causes include: 1. Servo software is not installed correctly or is corrupt. 2. Defective 1KB board. ⇒ Reinstall correct 1KB board servo software to the 1KA board. ⇒ Replace 1KB board. _____________________________________________________________________ ERROR CODE D2021 Arm data file is not found.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2024 [ARM CTRL BOARD] robot type setting failed. System software is not compatible with the robot model set in the AS software. ⇒ Ensure the correct model setting is used. ⇒ Ensure the correct software version is installed. _____________________________________________________________________ ERROR CODE D2025 Robot codes set in software and Arm ctrl board do not match.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2028 (SSCNET) initialization error. (code XX). The Mitsubishi single axis amplifier failed to initialize at controller power-up. A 2 byte code follows the error message. The higher byte indicates axis number and the lower byte indices the error code. Higher byte: 0: system error. Any other number: axis number that caused error. Lower byte: 1: 1LP daughter board not installed to 1KB board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2031 Codes set in software and on add’l pwr block mismatch. (Jt-A) Software and hardware settings, for the axis assigned to channel 7 (seventh axis), do not match power block settings. ⇒ Ensure correct power block is installed. ⇒ Ensure power block jumper settings are correct. ⇒ Use AUX 0804 or AS Language ID monitor command to ensure correct software version is installed.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D2035 Program execution error. Program failed to start when cycle start command was issued. ⇒ Reset the error, and restart the program. ⇒ If the error recurs, contact KRI Customer Service. _____________________________________________________________________ ERROR CODE D2036 (SSCNET) system error occurred in 1LP I/F board. (code XX) Main causes include: 1. Defective 1LP board (1KB daughter board) 2.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE D4502 FIELD-BUS-INIT) Error Reply. XX At fieldbus start-up, a mismatch in length of I/O data with the node at the end of the connection is detected when a message is sent to the fieldbus I/F card, or maximum I/O data length is exceeded. ⇒ Check the I/F card LED display. Match the I/O data length with the master. ⇒ Ensure I/O data length is within length specified for the fieldbus I/F card.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.3.2.2 EXXXX NON-FATAL ERROR CODES ERROR CODE E0001 Unknown error. Unregistered error occurred. ⇒ Contact KRI customer service (include operating conditions/settings and operation log at the time the error occurred). _____________________________________________________________________ ERROR CODE E0100 Abnormal comment statement exists.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E0103 Location data is not defined. Main causes include: 1. The location variable for the BASE, TOOL or POINT command is not specified. Example: “TOOL a” is specified and “a” is not defined. 2. DEST or #DEST function is used and the destination data is not defined. ⇒ Ensure all locations used in programs and functions are defined.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E0108 Divided by zero. Occurs when the system encounters a mathematical evaluation that involves division by “0”. Typically associated with the FRAME function and circular interpolation. ⇒ Check data source for calculations. _____________________________________________________________________ ERROR CODE E0109 Floating point overflow.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E0113 No expressions to evaluate. The type of data in an argument is incompatible with the operation being performed. ⇒ Correct the program to evaluate compatible expressions. _____________________________________________________________________ ERROR CODE E0114 SQRT parameter is negative. In the argument of a SQRT function, a negative number is entered for evaluation.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E0118 Too many subroutine calls. Occurs when more than 20 subroutines are nested with EXTCALL or CALL instructions. ⇒ Do not exceed 20 nested subroutines. _____________________________________________________________________ ERROR CODE E0119 Nonexistent subroutine. Displayed when the program specified by a CALL, ON, or ONI instruction does not exist.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1001 ADC input range error. This error occurs when an A/D converter input voltage is incorrect. The correct analog input voltage ranges are: 1. 0– +10 V 2. ±5 V 3. ±10 V ⇒ Ensure the correct analog input voltage range is used. _____________________________________________________________________ ERROR CODE E1002 PLC interface error.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1004 Interbus board is not ready. At 1JF board start-up, the board did not achieve the ready state within the required time. ⇒ Cycle controller power OFF and ON. ⇒ Ensure the 1JF board is correctly installed. ⇒ Replace the 1JF board. _____________________________________________________________________ ERROR CODE E1005 Spin axis encoder difference error.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1008 No.2 power sequence board is not installed. The first address of the No.2 1KP power sequence board cannot be read at controller power-up. Main causes include: 1. The 1KP power sequence board is not installed in the correct card slot. 2. Jumper or dip switch settings of the 1KP power sequence board are incorrect. 3. Defective 1KP power sequence board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1010 Power sequence board detects error. An error signal, not classified through the error summary, is generated by the 1KP board and is sent to the 1KB board. This error occurs when the error signal sent from the 1KP board is not recognized by the AS software. Main causes include: 1.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1013 InterBus board is not installed. The 1JF board is not installed. ⇒ Ensure the 1JF board is properly installed. ⇒ Replace the 1JF board. _____________________________________________________________________ ERROR CODE E1016 No. XX CC-LINK board is not installed. The specified number 1HS board is not installed. ⇒ Installed the specified number 1HS board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1021 Code Arm ID board error. (code XXX). Description 4AH Arm ID board data is not normal or is corrupt 4FH Writing error to arm ID board memor y1 C1H Communication check sum error2 C5H Communication protocol error2 C6H Communication response time-out error2 FFH Other errors (unknown error)3 1 Cannot write to arm ID board memor y. Replace arm ID board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1023 Communication error in robot network. Main causes include: 1. Communication between robots is not normal during cooperative motion operation. 2. Power to one of the controllers connected to the network is not set ON. ⇒ Ensure network cables and connections are correct. ⇒ Ensure robot network settings are correct. ⇒ Ensure power for all controller connected to the network is set ON.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1025 EXT AXIS connecting error. (code XX) Occurs when the gun axis connection is not normally completed. Code 0 Description No response from servo software. EF** Could not be executed because RGSO is ON. FF** Could not be executed because RGSO is ON. EE** Code pertaining to other than release/connection. FE** Code pertaining to other than release/connection.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1027 Safety circuit was cut OFF. The safety gate branch of the safety circuit is open due to a missing safety plug or defective circuit. ⇒ Reinsert the safety plug. ⇒ Repair open circuit. _____________________________________________________________________ ERROR CODE E1028 Jt XX Motor overload. The current feedback from the power block exceeded maximum continuous ratings longer than the time allowed.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 6. Malfunction of the motor. 7. Servo spot weld gun: –Clamping pressure and/or clamping time is excessive. –Distance between weld points is short; the motor does not have time to cool sufficiently between welds. –Clamping pressure setting exceeds the servo gun motor power capacity. ⇒ Check the cyclo reduction unit, the gear, or the bearing(s) for mechanical failure. Replace as necessary.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E1029 Encoder rotation data is abnormal. (Jt XX) Occurs when there is a difference (+2 rotations or more) between the rotation data in the serial encoder data and the rotation data calculated using the incremental technique.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1030 Encoder data abnormal. (Jt XX) When control power is switched ON, the current encoder value is compared to the stored encoder value when the power is turned OFF. If the difference is more than the value set in AUX 0504 Encoder Error Range, or by the ENCCHK_DATA command, this error occurs.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E1031 Miscount of encoder data (Jt XX). The servo gun or tool changer harness is defective. ⇒ Inspect the servo gun and tool changer harnesses; replace if necessary. _____________________________________________________________________ ERROR CODE E1032 Mismatch ABS and INC encoder data (Jt XX).
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1034 Encoder initialize error (Jt XX). The encoder is not able to read the absolute position at control power on. The scanning of absolute data begins immediately after a shift from the state of non-operation, or back-up operation, to normal encoder operation. BUSY=1 is output until the absolute position has been determined.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E1035 Encoder response error (Jt XX). Occurs when the encoder does not respond, or response is slow, to data request signal from the 1KB board. Encoder Servo CPU Encoder Encoder I/F 1KB board Encoder +12 VDC power supply Controller Power circuit Battery 1FG/1HG board Robot Main causes include: 1. Defective encoder or encoder harness. 2. Defective 1KB or 1FG/1HG board. 3. Noise related malfunction.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1036 Encoder communication error. (Jt XX) Cyclic redundancy check (CRC) fault or framing error is detected in communication with the encoder. Encoder Servo CPU Encoder Encoder I/F 1KB board Encoder +12 VDC power supply Controller Power circuit Battery 1FG/1HG board Robot Main causes include: 1. Noise related malfunction. 2. Defective encoder or encoder harness. 3. Defective 1KB or 1FG/1HG board.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E1037 Encoder data conversion error. (Jt XX). This error is caused by abnormal encoder absolute position data. Encoder Servo CPU Encoder Encoder I/F 1KB board Encoder +12 VDC power supply Controller Power circuit Battery 1FG/1HG board Robot Main causes include: 1. Noise related malfunction. 2. Defective encoder or encoder harness. 3. Defective 1KB or 1FG/1HG board. 4. Servo spot weld gun.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1038 Encoder ABS-track error. (Jt XX) The absolute data and the incremental data in the encoder are different. ABSALM=1 is output from the encoder when this error occurs. Encoder Servo CPU Encoder Encoder I/F 1KB board Encoder +12 VDC power supply Controller Power circuit Battery 1FG/1HG board Robot Main causes include: 1. Noise related malfunction. 2. Defective encoder or encoder harness. 3.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E1039 Encoder INC-pulse error. (Jt XX) Occurs when the encoder A and B incremental pulses are abnormal. The encoder INALM bit is sent with the serial data=1. Encoder Servo CPU Encoder Encoder I/F 1KB board Encoder +12 VDC power supply Power circuit Battery 1FG/1HG board Controller Robot Main causes include: 1. Noise related malfunction. 2. Defective encoder or encoder harness. 3.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1041 Limit switch (JT XX) is ON. This error occurs when the robot moves beyond the set working range (restricted space) and activates the axis restriction limit switch. The mechanical stopper and the axis restriction limit switch are optional and the axis they are installed on varies with machine type and configuration.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E1042 Limit switch signal line is disconnected. This error occurs when the axis restriction limit switch is activated and the robot did not move beyond the set working range (restricted space). The mechanical stopper and the axis restriction limit switch are optional and the axis they are installed on varies with machine type and configuration.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1045 Gun-clamp Mismatch. (Spot weld specifications type B) Spot weld is not selected in AUX 0605-1 when a servo spot weld gun is used. ⇒ Ensure spot weld is selected in AUX 0605-1. _____________________________________________________________________ ERROR CODE E1046 Too short distance between start point and end point.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1050 Encoder and brake power off signal not dedicated. A gun change is executed on a servo spot weld gun without setting [Encoder and brake power (7)] dedicated signal in AUX 0602. ⇒ From AUX 0602 Dedicated output Signals, set the [Encoder and brake power (7)] signal to dedicated and enter the signal number.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1054 Cannot execute motion instruction. Main causes include: 1. A motion instruction is executed for the slave robot during cooperative motion. 2. A motion instruction is executed in soft absorber mode (from SASTART to SAEND). ⇒ Correct the slave robot program. Only non-motion instructions can be used for the slave robot in the cooperative motion program.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1058 SLAVE robot already exists. This error occurs when SLAVE instructions are executed for both connected robots during cooperative motion in repeat mode. ⇒ Do not execute SLAVE instructions for both robots at the same time. _____________________________________________________________________ ERROR CODE E1059 Not an instruction for cooperative motion.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1063 JT2 and JT3 interfere during motion to end pose. Movement from the current position to the end pose would cause JT2 and JT3 to move beyond their limits. ⇒ Modify the position of the end pose of the program. _____________________________________________________________________ ERROR CODE E1064 Illegal pallet number.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1067 Illegal pattern type. Main causes include: 1. Program step does not comply with AS Language syntax. 2. Pattern type for work specified using block step instructions or the PALLET function is not between 1 and 5. ⇒ Refer to the D Series Controller AS Language Reference Manual for proper use of the AS Language commands. ⇒ Ensure the work pattern number specified is correct.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1071 XMOVE signal is already input. An XMOVE instruction mode “/ERR” is specified and the signal condition to monitor is already attained when monitoring starts. ⇒ Delete the “/ERR” mode from the XMOVE instruction or specify “/LVL” mode. ⇒ Modify the program so the signal condition is not attained until monitoring starts.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1076 Cannot use negative time value. Displayed when a negative number is entered as part of a DELAY or TIMER command. ⇒ Correct the time setting to a positive number. _____________________________________________________________________ ERROR CODE E1077 No value set. Occurs when an instruction like the BITS command is evaluated and there is no corresponding value set.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1081 Cannot use negative value. Displayed when a negative number is used in conjunction with the PULSE or ACCURACY commands/instructions. ⇒ Use only positive numbers in the acceptable range for the PULSE and ACCURACY commands/instructions. _____________________________________________________________________ ERROR CODE E1082 Out of absolute lower motion range limit.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1086 Start point for Jt XX beyond motion range. Robot pose at motion start is beyond the range set in AUX 0507. Example: DO HOME is executed at a point that is out of motion range set in AUX 0507. ⇒ Correct pose to within working envelope or expand software limits to accept pose.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1090 External modulation data is not input. (Option) External modulation data is not received. ⇒ Check for abnormality in the external modulation data line and repair as necessary. _____________________________________________________________________ ERROR CODE E1091 External modulation data is abnormal. (Option) Modulation data is too large.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1095 Cannot execute motion instruction in PC program. A PC program cannot contain instructions that initiate robot motion. ⇒ Correct the PC program by removing motion instructions. _____________________________________________________________________ ERROR CODE E1096 Incorrect auxiliary data settings. The value selected for auxiliary data (speed, timer, tool etc.) exceeds allowable range.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1100 Cannot execute in sealing specification. Occurs when a CLOSE(I), OPEN(I), or RELAX(I) command is executed in a program and clamp specifications in AUX 0605-1 are set for sealing. ⇒ Correct program instructions to match software configuration. _____________________________________________________________________ ERROR CODE E1101 Can only execute in sealing specification.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1106 Cannot execute in this robot. This error occurs when a request is executed on a robot arm that does not support the function. ⇒ Contact KRI customer service to have the function installed or delete the request. _____________________________________________________________________ ERROR CODE E1108 Duplicate robot network IDs.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1113 Work sensing signal is not detected. (sensing function) This error occurs when the X-linear step is executed and the workpiece is not detected before the robot axes reach coincidence of the taught point. The sensing device or sensing device harness may be defective. ⇒ Set the accuracy range to a smaller value. ⇒ Repair or replace sensing device or sensing device harness.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1117 Process time over. Lack of system processing time ⇒ Contact KRI customer service (include operating conditions/settings and operation log at the time the error occurred). _____________________________________________________________________ ERROR CODE E1118 Command value for Jt XX suddenly changed.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1119 Commanded value for Jt XX beyond motion range. Spot Welding and Material Handling The commanded position for the joint identified exceeds the software limits. Condition is monitored in both the check and repeat modes. ⇒ Correct taught positions to avoid the software limits. ⇒ Adjust the software limits in AUX 0507 to provide the necessary motion range.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1122 Unexpected motor power OFF. Occurs when software turns motor power ON (K1 or K2 contactors ON) but there is no signal feedback (MCON) indicating motor power is ON. Main causes include: 1. Defect in the 1KP power sequence board. 2. Defect in the 1KQ/1NQ relay board. 3. Malfunction in the error detection circuit and error processing of 1KP/1KQ board. 4.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1124 Deviation error of Jt XX. Spot Welding and Material Handling The difference between the current value from the encoder and the command value in the AS software exceeds the regulated value (varies by robot model). Main causes include or the following abnormalities: Mechanical 1. Singularity motion. 2. The robot arm has contacted an external item hindering movement. 3.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1126 Commanded speed error Jt XX. This error occurs when the positional command value sent to the 1KB board from the 1KA board exceeds the value range. Main causes include: 1. A sudden change in robot motion. 2. Defective 1KA/1KB board. 3. Corrupt AS software caused the commanded speed value to exceed motor capacity rating. ⇒ Modify program data to eliminate sudden changes in robot motion.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1128 Uncoincidence error betw destination and current Jt XX pos. This error occurs during program execution, if all joints do not reach total coincidence within the commanded accuracy and time. Main causes include. Mechanical1. Damaged bearings. 2. Insufficient gear backlash. 3. Motor brake not released. 4. Arm movement restricted by harnesses or peripheral devices. Electrical1.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1130 Jt XX collision was detected. Motor current command value exceeds the threshold value set in AUX 0510. ⇒ Remove obstacles in the robot motion path area. ⇒ Ensure tool settings are correct. ⇒ If an obstacle was not encountered, increase the threshold value set in AUX 0510. _____________________________________________________________________ ERROR CODE E1131 Jt XX Unexpected shock is detected.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1134 Abnormal work transfer pitch. The signal for resetting the conveyor value is received before the conveyor reached the position specified by the work transfer pitch. ⇒ Ensure the work transfer pitch is set correctly. ⇒ Modify program data as necessary. _____________________________________________________________________ ERROR CODE E1135 Motor power OFF.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1138 Aux. terminal is not connected. External monitoring device is not connected. ⇒ Ensure the external monitoring device is properly connected. _____________________________________________________________________ ERROR CODE E1139 DA board is not installed. (Option, analog voltage output) Main causes include: 1.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1143 Conveyor axis number is not set. Conveyor axis number is not set at execution of conveyor synchronous motion. ⇒ Set the conveyor axis number using the ZCVAXIS instruction. _____________________________________________________________________ ERROR CODE E1144 No arm control board. ⇒ Ensure the 1KB arm control board is properly installed. ⇒ Replace the 1KB board. ⇒ Replace the 1KA board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1149 Cannot open setting data, so cannot set to shipment state. When “2: Setting to shipment state” is selected from the initialization screen, a data file in the setting file (ini_load.cmd) in the 1KA board memory could not be opened. ⇒ Ensure the proper setting file (ini_load.cmd) is loaded into the 1KA board memory.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1154 Option SIO port is not installed. Main causes include: 1. Optional communication port (1GS board) is not installed to the 1KA board. 2. Optional communication port (1GS board) is not recognized by the 1KA board. ⇒ Install the optional communication port (1GS board) onto the 1KA board. ⇒ Replace the 1KA board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1157 Code Arm ID I/F board error. (code XXX) Description C1H Communication check sum error1 C5H Communication protocol error1 C6H Communication response time-out error1 FFH Other errors (unknown error)2 1 Damaged or disconnected communication cable. 2 F*H cycle controller power ON and OFF.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E1162 Buffer overflow occurred gravity comp. value channel XX. Gravity compensation value overflow due to mismatch of load weight and the set value. ⇒ Contact KRI customer service (include operating conditions/settings and operation log at the time the error occurred). _____________________________________________________________________ ERROR CODE E1163 Robot stopped in checking operational area.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E1167 Unable to download ext. axis parameter. (Jt-B) Download failed due to channel 8 parameter is being downloaded by another process. ⇒ Re-execute parameter download. ⇒ If this error recurs, contact KRI customer service. _____________________________________________________________________ ERROR CODE E1168 Num. not assigned to specified channel. (Jt-B) Channel is not assigned an axis number.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4000 Data communication error. Main causes include: 1. When receiving data from vision sensor: –Time out occurred, data is not received within the specified time. –Robot is stopped by HOLD, ABORT or PCABORT during data communication. –Robot stopped by the CONTROL key or ENTER key from a PC keyboard during data communication 2.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4004 Communication retry error. Communication retry error during Host Communication I. Main causes include: 1. No response after sending text. 2. After text is sent, NAK (resend request) exceeded the allowed number of retries. ⇒ Ensure communication protocol used for Host Communication I is correct. ⇒ Check the communication cable and replace as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4009 Communication time out error. During Host Communication I or TCP/IP interface, data is not received within the allowed time after executing the RECEIVE instruction. ⇒ Ensure communication protocol used for Host Communication I is correct. ⇒ Reserve the communication line. _____________________________________________________________________ ERROR CODE E4010 Terminal already in use.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4014 TELNET) RECV error. CODE=XX. During TCP/IP communication, data is not received due to a RECV (receive) error. ⇒ Check the communication line to the target end node and repair as necessary. ⇒ Check for problems at the target end node and repair as necessary. ⇒ The sub-error code (CODE=XX) is generated by the TCP/IP package. Refer to the TCP/IP package manual.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4018 TELNET) System error. CODE=XX. Parameter settings entered using the NETCONF command does not comply with AS Language syntax. The code (CODE=xx) indicates a detailed SUB error code for the TCP/IP package. ⇒ Refer to the TCP/IP package manual. ⇒ Ensure the parameter settings are entered in compliance with AS Language syntax.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4021 TCP/IP) Communication Error. CODE=XX Dst.IP=xx.xx.xx.xx. A communication error occurred during execution of the UDP_SENDTO/ UDP_RECVFROM/TCP_SEND/TCP_RECV instruction. May be a problem with the Ethernet line or at the target end. ⇒ Check the communication line to the target end node and repair as necessary. ⇒ Check for problems at the target end node and repair as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4025 TCP/IP) Connection aborted. Communication is disconnected during execution of the UDP_SENDTO/ UDP_RECVFROM/TCP_CONNECT/TCP_SEND/TCP_RECV/TCP_ACCEPT instruction. May be a problem with the Ethernet line or at the target end node. ⇒ Check the communication line to the target end node and repair as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4029 FTP) Data send error. (code=XX). Failure to transmit the teach data via Memory→LAN (Manual SAVE). May be a communication cable connection problem. ⇒ Ensure the communication cable connections are correct and re-execute. _____________________________________________________________________ ERROR CODE E4031 FTP) Failed to disconnect with FTP server.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4034 FTP) failed to receive HOST OS information. (code=XX) Error occurred during receiving OS information from the server. ⇒ Ensure the communication cable is properly connected, and re-execute. ⇒ Reboot the FTP server. _____________________________________________________________________ ERROR CODE E4036 FTP) FTP service busy now. A command is being executed by the server.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E4052 [FDD/PC_CARD] Failed to set verify function. Please set again. Failure to set condition for verify function for the 1KF board. ⇒ Re-set condition for verify function in AUX 0208. _____________________________________________________________________ ERROR CODE E4053 Channel error. A monitor or program instruction is executed on an unavailable channel.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4056 TCP) This port is not in LISTEN (SOCK). Main causes include: 1. Failure to open the socket when executing TCP_ACCEPT. 2. Failure to close the socket when executing TCP_END_LISTEN. ⇒ Ensure correct port number is used. ⇒ Ensure the parameter settings are entered in compliance with AS Language syntax.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4501 ANYBUS) OUT/FB.CTRL release timeout. XX Access to the input signal reading area is not released due to defective hardware. ⇒ Check LED indicator on the interface card, and reset the error. ⇒ If the error message is still displayed contact KRI customer service, include the subcode XX. _____________________________________________________________________ ERROR CODE E4510 DN) Master status.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4521 ABMA-PDP) Status OFFLINE. XX An error occurred in the ABMA-PDP module, and the status of AnyBus PROFIBUS-DP master changed to OFFLINE. ⇒ Use the sub-sub-code XX as a troubleshooting aid, clear the cause of the error and reset the error. ⇒ If the error recurs, cycle the controller power OFF and ON.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4525 ABMA-PDP) Timeout of sending message. XX ABMA-PDP module overload, sending message cannot be processed within the allowed time. ⇒ Check the fieldbus cable and connections, repair/replace as necessary. ⇒ Use the sub-code XX as a troubleshooting aid, clear the cause of the error and reset the error.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E4529 PROFIBUS) Statistic counter-error response detected. XX Incorrect slave diagnosis command parameter is entered. ⇒ Use the sub-code XX as a troubleshooting aid, clear the cause of the error and reset the error. ⇒ Ensure the correct parameters and node address are used. _____________________________________________________________________ ERROR CODE E4530 DN) DeviceNet cable is disconnected.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5003 Illegal extend (retract) output signal. Occurs when the output signals for the extend and retract operation of a spot welding application are not properly set. ⇒ Check the setting in AUX 0605. _____________________________________________________________________ ERROR CODE E5004 Weld completion signal already input.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5007 Servo weld gun not connected or wrong gun connected. (Servo spot weld gun only) Main causes include: 1. The robot executes a step when a gun is not attached to the tool changer. 2. The gun number in the tool changer is different than the gun number specified for the program step. 3. Incorrect gun number is read due to damaged gun harness.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5010 Servo weld gun mechanical parameter is not set. (Servo spot weld gun only) A new gun is connected and the mechanical parameters are not defined in AUX 1021. ⇒ Define the parameters in AUX 1021. _____________________________________________________________________ ERROR CODE E5011 This clamp number already set for servo weld gun axis.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5015 Gun status data disagrees with clamp condition. (Servo spot weld gun only) Incorrect program data is used. Main causes include: 1. Clamp ON is taught in a step that includes a gun change. 2. Clamp OFF is taught in a step that includes a point for “wear measurement using automatic clamping”, “wear measurement reference plate”, or “work position deviation measurement”.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5018 Weld completion signal has not been detected. Occurs when a weld complete signal is not received in the allowed time period. Main causes include: 1. Defective weld gun, weld controller/timer, cable, etc. 2. Defective 1KA/1GW (1HW) boards, or harness, etc. 3. Defective interlock circuit. 4. Noise related malfunction. ⇒ Check gun, weld controller/timer, cable, etc. and repair/replace as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5021 Extend pos. monitor error. Occurs when the input signal for the extend operation of a 2-stroke retractable gun is not received. Main causes include: 1. Defective weld gun, weld controller/timer, cable, etc. 2. Defective 1KA/1GW (1HW) boards, harness, etc. 3. Defective interlock circuit. 4. Incorrect extend position input signal setting. 5. Noise related malfunction.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E5024 Pressurization comp. signal has not been detected. Pressurization completion signal is not received from the weld controller/timer. Main causes include: 1. Defective weld controller/timer. 2. Defective servo spot weld gun. 3. Defective harness, cable, etc. ⇒ Check weld controller/timer, servo spot weld gun, harnesses, and cables and repair/ replace as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5027 Robot stopped during weld. (Spot weld specifications type C) (Servo spot weld gun only) This error occurs when the robot is placed in a HOLD or an E-STOP condition after the clamp output signal is sent, and before the weld complete signal is received. ⇒ Return the system to normal operation and re-execute weld.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE E5030 Copper plate wear exceeds limit. step=XX. (Servo spot weld gun only) The copper backing plate wear exceeds the copper plate wear limit (AUX 1029). The error is detected when the gun executes a weld. ⇒ Replace the copper backing plate. _____________________________________________________________________ ERROR CODE E5031 Weld completion signal is not turned off.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E5033 Cannot weld because of abnormal thickness. (Servo spot weld gun only) The thickness of the workpiece is out of tolerance. Main causes include: 1. Defective workpiece. 2. Incorrect positioning of the workpiece. 3. A gap between the two panels being welded. 4. Current tip wear (AUX 1029) and actual tip wear are different. ⇒ Inspect the workpiece.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6002 Signal condition already input. The signal condition is already met when an XDMOVE or XD(2)START move is executed and the signal monitoring starts. ⇒ Check input signal timing for the door open detection signal and the monitored signals, and correct interlock data or program data as necessary.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6007 Wrist can’t be straightened any more (Singular point 1). The posture of JT5 is set too close to 0 degrees (or a multiple of 360 degrees) on a robot equipped with a 3S type wrist. NOTE This does not normally occur in joint mode, but may occur with conveyor synchronous function enabled. ⇒ Change wrist posture. ⇒ Move the robot in joint interpolation.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6012 Relative distance between guns is too near. The gun tips of two networked robots is less than the minimum specified distance for the application. ⇒ If this error occurs in teach mode, drive the axes so the distance between gun tips is within specified value. ⇒ If this error occurs in check/repeat mode, modify the program data, and change the motion timing and relative distance.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6502 Arc failure. The signal (current detection: WCR) that indicates the robot is executing the weld was not returned from the weld controller/timer within 1 second, or less, after welding started. Main causes include: 1. Arc is not generated when welding starts. 2. Arc generation is interrupted for 1, or more, seconds during welding.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6505 Arc weld insulation defect. This error occurs when robot movement causes insulation failure. ⇒ Ensure the welder, torch, and robot insulation are in good working condition. _____________________________________________________________________ ERROR CODE E6506 Torch interference. The limit switch for torch interference detection is tripped or damaged.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6510 Undefined sensing direction. (Touch sensing) Occurs when the step proceeding the WORK_DETECT instruction is not an air_cut point. ⇒ Insert an air_cut point in the program before the WORK_DETECT instruction. ⇒ When using step select to chose the start step, select the air_cut point before the WORK_DETECT instruction in the program.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6512 Undefined mother or daughter work. (Touch sensing) Main causes include: 1. A previous work instruction is not completed before another work instruction is executed. 2. Program execution is started at a step in that does not allow completion of a previous work instruction. Example: 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6514 Work specification incorrect. (Touch sensing) Occurs when a previous work instruction is not completed before another work instruction is executed. Example: 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 3. AC LINEAR SPEED9 ACCU4 TIMER0 4.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6516 Wire check failure. (Touch sensing) Main causes include: 1. The position of a taught point is recorded too far from the workpiece, and the wire tip did not touch the work within the allowed time. 2. The weld wire is not sent due to the welding unit power off etc. ⇒ Reteach point at the correct distance. ⇒ Ensure workpiece is within specifications and is properly placed.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6519 Weld condition data out of range. Ensure data is within range as shown below. Current: Voltage: Speed: Time: Weaving width: Weaving frequency: Weaving pattern: 0–999 Amp 0–99.9 Volt 0–999 cm/min 0–9.9 second 0–40.0 mm 0–4.0 Hz 0–9 ⇒ Correct weld condition data as necessary. _____________________________________________________________________ ERROR CODE E6520 Laser sensor tracking value exceeded.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6522 Laser sensor cannot detect welding joint. Main causes include: 1. The laser sensor unable to find a groove. 2. The laser sensor detects a groove that does not match the specified groove number data. 3. The laser sensor controller EMERGENCY STOP switch is pressed. 4. Incorrect laser sensor settings or defective laser sensor. ⇒ Re-teach the groove data. ⇒ Ensure the correct groove number is specified.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6526 No response from laser sensor controller. Main causes include: 1. Disconnected or defective laser sensor harness. 2. Incorrect laser sensor settings or defective laser sensor. ⇒ Check laser sensor, laser sensor harness and connections and repair/replace as necessary. ⇒ Refer to the laser sensor operation manual and ensure correct set-up and operation procedures are used.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6529 Finish point not found by laser sensor. Main causes include: 1. The laser sensor unable to find a groove. 2. Auto tracking function is enabled with no data present, and finish point detection failed. ⇒ Re-teach data, or readjust the detection range for the finish point. ⇒ Disable auto tracking function ID because there is no data, and re-execute finish point detection.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6533 No RTPM board. Main causes include: 1. The software for RTPM option is installed, but the hardware (1FH board) is not installed properly. 2. Hardware for RTPM (1FH board) is installed, but the software for RTPM option is not installed. 2. The software and hardware (1FH board) are installed, but controller power was not cycled OFF and ON after RTPM option is set-up.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6536 RTPM current deviation error. Occurs when actual current exceeds commanded current (feedback current) for a time period exceeding the current deviation error time-out value. Main causes include: 1. Weld start-point is too far from the groove. 2. Defective weld controller/timer, or weld controller/timer set OFF. 3. Incorrect linearization or offset/gain.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6538 Beyond RTPM tracking ability. Occurs when the current tracking value exceeds the threshold value and the number of times value set for RTPM tracking ability errors. Example: If the threshold is set at 9 mm, and the number of times is set at 30, the error occurs after 30 weave cycles and the path deviates more than 9 mm from the original welding path. Main causes include: 1.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6540 Beyond AVC tracking ability. Occurs when the current tracking value exceeds the threshold value and the number of times value set for RTPM tracking ability errors. Main causes include: 1. Weld start-point is too far from the groove. 2. Defective weld controller/timer, or weld controller/timer set OFF. 3. The deviation error detection value is set too low.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E6543 Too many taught points for AVC. Occurs when the number of taught points between the weld start point and the weld end point exceeds 127 points. ⇒ Reteach program points, not to exceed 127 RTPM points. _____________________________________________________________________ ERROR CODE E6562 Electric pole stuck. The electrode is stuck to the base metal during TIG welding. ⇒ Cut the electrode.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE E8200 Not in cooperative mode. Cooperative motion instruction is taught before MASTER/SLAVE instruction or after ALONE instruction. ⇒ Use cooperative motion instructions between MASTER/SLAVE instruction and ALONE instruction.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.3.2.3 PXXXX OPERATION ERROR CODES ERROR CODE P0100 Illegal input data. AS Language command/instruction does not comply with AS Language syntax. ⇒ Enter AS Language command/instruction in correct AS Language syntax. _____________________________________________________________________ ERROR CODE P0101 Too many arguments.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE P0106 Illegal priority. Priority level designation is out of the allowable range (1–127). Example: LOCK 128 ⇒ Ensure the correct priority level number is entered (1–127). Example: LOCK 2 _____________________________________________________________________ ERROR CODE P0107 Invalid coordinate value. Upper limit value is less than lower limit value for work space output data.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0111 Cannot use this command/instruction in current mode. The command/instruction entered could not be executed in the selected mode. Example: “EDIT” is entered in the program edit mode (used in monitor mode). Example: “TERMOFF” is entered from the teach pendant keyboard (used from a PC terminal). ⇒ Ensure correct mode is selected.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0117 Invalid variable (or program) name. Displayed when illegal variable or program name is entered from the editor or monitor modes. Example: “JM ##a” too many precision point symbols. Example: “CALL #a” is not an acceptable program name. ⇒ Ensure program names and variables are defined correctly.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0121 Expected to be a binary operator. A non-binary operator has been entered where a command expected a binary operator. ⇒ Enter a binary operator. _____________________________________________________________________ ERROR CODE P0122 Illegal constant. A variable, or a non-constant, is used where a constant or integer should be used with a monitor command. Example: “WHERE a” Should be WHERE 1 … WHERE 6.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0126 Illegal switch name. Displayed when a system switch is incorrectly identified. Example: “SWITCH light” there is no system switch named “light”. ⇒ Use valid switch names. _____________________________________________________________________ ERROR CODE P0127 Specified switch name needs full spelling. System switch name entered does not comply with AS Language syntax.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0131 No. of dimension in array exceeds 3. Attempted to create an array variable with more than 3 dimensions. Example: “point[3,5,7,9]=1” returns an error. ⇒ Use 3 or less dimensions (elements) in an array. Example: “point[1,2,3]=1” is correct and does not return an error. _____________________________________________________________________ ERROR CODE P0132 Array variable already exists.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0135 Local variable expected. A global variable is used when defining a temporary argument for a subroutine. Example: “SUB(a)” returns an error. ⇒ Use a local variable when defining a temporary argument for a subroutine. Example: “SUB(.a)” is correct and does not return an error. _____________________________________________________________________ ERROR CODE P0136 Unexpected suffix.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0139 Illegal control structure. Main causes include: 1. In a control structure CASE is the last step, or VALUE, END, or ANY are missing after CASE. 2. Destination step for structure instruction is missing. ⇒ Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE P0140 Step:XX Wrong END statement.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0144 Step:XX Preceding IF missing. Displayed when control flow structure does not contain the correct structure for IF…THEN… ELSE…END commands. ⇒ Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE P0145 Step:XX Preceding CASE missing.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0149 Variable (or program) already exists. The name of a program, loaded from floppy disk or PC card using the LOAD command, already exists in the system memory. This error is not used in the spot welding application. ⇒ Change the name of the program currently in system memory. ⇒ Delete the program in system memory, if not needed.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE P0153 Illegal clock value. Time or date is entered in the wrong format. ⇒ Re-enter the values correctly; time—military, date—yy/mm/dd. _____________________________________________________________________ ERROR CODE P0154 Missing “=”. The argument is missing the necessary “=”. Example: “XFER test sub” returns an error. ⇒ Ensure command/instruction complies with AS Language syntax and format.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P0158 Missing “BY”. The argument is missing the necessary “BY”. Example: “POINT y = SHIFT (x 5,5,5) ⇒ Ensure command/instruction complies with AS Language syntax and format. Example: “POINT y = SHIFT (x BY 5,5,5) _____________________________________________________________________ ERROR CODE P0159 Missing “:”. The argument is missing the necessary “:”. Example: “SEND 1 $out,err” returns an error.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE P0162 Cannot modify position data in this instruction. During modifying an AS Language program from the teach screen, pose data is modified at a step with a non-positional command/instruction. Example: Trying to modify pose data, at a step with “DELAY 1” recorded, returns an error. ⇒ Pose data can only be modified for AS Language program steps containing move instructions (JMOVE, LMOVE, etc.).
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P1003 Cannot execute a program because of EXT.HOLD input. An attempt to cycle start a program is made while external hold signal is ON. ⇒ Release the external hold and re-execute cycle start. ⇒ Verify dedicated input signals in AUX 0601 match signals programed from the PLC in the Slogic program. ⇒ If the external hold signal is not needed, change the signal setting in AUX 0601 from set to reset.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P1009 Program is already running. Main causes include: 1. An attempt is made to edit or execute a program that is running. 2. SYSINIT command is executed while a program is running. ⇒ Stop the robot control program prior to editing or checking. ⇒ Stop the robot control program prior to executing the SYSINIT command.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P1014 Cannot execute because program already in use. An attempt to execute the same program using the EXECUTE and PCEXECUTE is made. ⇒ Allow the program to complete executing and re-execute. _____________________________________________________________________ ERROR CODE P1015 Cannot delete, in use by another command. Cannot COPY, DELETE or XFER command because program is being edited or executed.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING ERROR CODE P1019 PC program is running. Occurs when a PC program is running and instructions are entered that are not allowed. ⇒ Allow the PC program to complete execution and re-enter the instructions. ⇒ Stop the PC program and re-enter the instruction. _____________________________________________________________________ ERROR CODE P1020 Cannot operate because teach pendant in operation.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P1024 Statement cannot be executed. Occurs when the AS Language instruction entered is not acceptable for the mode of operation. Example: DO HOME is executed with TEACH LOCK ON. ⇒ Use instructions and commands that are compatible with the selected mode. _____________________________________________________________________ ERROR CODE P1025 Cannot be executed, function not set.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P1029 Program name not specified. Displayed when no program is on the stack and the EDIT command is entered without specifying a program name. ⇒ Specify the name of the program to edited. _____________________________________________________________________ ERROR CODE P1030 Program interlocked by other procedure.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P1034 This program is not editable. The auto load measurement program cannot be edited. ⇒ Use a program name that does not include the auto load measurement program name. _____________________________________________________________________ ERROR CODE P1035 Record inhibited. Set [record accept] and operate again.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P1039 Teach pendant is not connected. The “T” command is executed without the teach pendant connected. ⇒ Install teach pendant and re-execute the “T” command. _____________________________________________________________________ ERROR CODE P1040 Cannot execute this command in I/F panel. A monitor-command button is set-up on the I/F panel to execute a command that is not permitted from the I/F panel.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2000 Turn OFF motor power. An attempt is made to execute an operation or command which is not permitted with motor power ON. Example: ZZERO command. ⇒ Turn motor power OFF and re-execute operation or command. _____________________________________________________________________ ERROR CODE P2001 Turn HOLD/RUN sw. to HOLD.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2006 Option is OFF. Selected option is set OFF (disabled) or is not installed. ⇒ Enable option or contact KRI customer service to install option. _____________________________________________________________________ ERROR CODE P2007 Cannot execute because executed by other device. Occurs when the operator attempts to execute the same command from the KCWIN terminal and the teach pendant at the same time.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2011 Invalid disk format. Incorrect disk format. ⇒ Ensure the disk format is: 2HD, 1.44 MB or 1.25 MB. _____________________________________________________________________ ERROR CODE P2012 Disk is write protected. This error occurs when attempting to write to a disk that is write protected. ⇒ Disable the write protection on the floppy disk card.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2016 Cannot open the file. The file cannot be opened with the SAVE or LOAD commands. ⇒ Ensure the floppy disk is properly inserted into the floppy disk drive. ⇒ Ensure an existing file name is used. ⇒ Defective local bus harness. ⇒ Defective floppy disk, floppy disk drive unit, or 1KA board. _____________________________________________________________________ ERROR CODE P2017 Cannot close the file.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2022 Cannot use DOUBLE OX. When DOUBLE type signals are used, if either output signal in the pair is set ON, the other is set to OFF. An instruction (BITS, PULSE, DLYSIG, etc.) to change the state of either output signal causes this error to occur. ⇒ Ensure signals used with the BITS, PULSE, DLYSIG, etc. commands/instructions are not designated as DOUBLE OX.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2026 Invalid coordinate value Z. This error occurs when the work space output signal lower Z value is greater than the upper value in AUX 0403. ⇒ Ensure upper and lower values are set correctly in AUX 0403. _____________________________________________________________________ ERROR CODE P2027 Cannot use signal, already used in I/F panel.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2032 Incorrect number input as WHERE parameter. Occurs if a numeric value entered with the WHERE command is not in the acceptable range. Example: WHERE 100. ⇒ Ensure that data is within acceptable range. Example: WHERE 1. _____________________________________________________________________ ERROR CODE P2033 Logging is running.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2039 Cannot start cycle from FN instruction. This error occurs when an FN instruction is the first step at cycle start. ⇒ Do not execute cycle start at a step containing an FN instruction. _____________________________________________________________________ ERROR CODE P2040 Card is not ready. The controller tried to read the PC card, but the PC card is not inserted. ⇒ Insert PC card and re-execute.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2045 Cannot format this card. An attempt is made to format a non-SRAM PC card. ⇒ Use a PC to format a non-SRAM card. _____________________________________________________________________ ERROR CODE P2046 Card initialization error. PC card format failed. ⇒ Re-execute PC card format. ⇒ If the error recurs, use another PC card.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2051 Illegal sequence numbers for file I/O data. During data transfer between the 1KA and 1KF boards, the response from the 1KF board does not conform to the request from the 1KA board. ⇒ Replace the 1KA/1KF boards. ⇒ Replace the harness between the 1KA and 1KF boards. ⇒ Check for noise malfunction and shield integrity.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2055 [LSEQ] Program is already running. During execution of the basic operation part of the sequence function of the KLogic program, the program is executed again by the LSQEXECUTE command/instruction. ⇒ Place the basic operation part of the sequence function in HOLD and re-execute. ⇒ Correct the currently running program using the LSQREWRITE command.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2059 [SerialFlash] data write error. The specified file cannot be written to the 1KA board. Main causes include: 1. The file is corrupt. 2. The serial flash memory on the 1KA board is set to write-protect. ⇒ Ensure the 1KA board serial flash memory is not set to write-protect. ⇒ Replace the 1KA board serial flash memory.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2064 [FDD] No space available. Floppy disk has less than 12 KB of free space and the data cannot be saved. ⇒ Insert a floppy disk with sufficient free space and re-execute. ⇒ Delete unnecessary data from the floppy disk and re-execute. _____________________________________________________________________ ERROR CODE P2065 [Multi Disks] Invalid disk was loaded.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2069 [FDD/PC_CARD] Device already in use. Attempting to perform several processes at the same time to/from the floppy disk/PC card. The next task is commanded while the previously commanded task is in progress. ⇒ Allow each task to be completed before initiating another task to/from the floppy disk/ PC card.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P2074 Floppy disk is broken. This error occurs when ten or more defective sectors are detected on a floppy disk. ⇒ Use a new or known good floppy disk. _____________________________________________________________________ ERROR CODE P2075 Channel number of JtXX is incorrect. Main causes include: 1. Non-existing channel number is allocated. 2.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P4502 DEVNET) Already in that mode. An attempt is made to change the operation mode setting, using the DEVNET command, to the mode that is currently set. ⇒ Ensure the correct parameter is set and re-execute the DEVNET command. _____________________________________________________________________ ERROR CODE P4503 Duplicate signal number.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P5002 Spot sequence is running. Step change, program change, or program execution attempted while the spot weld sequence is executing (after Retract/Extend input signal and weld complete signal are received). Example: The robot is executing motion start delay time after weld complete. ⇒ Perform step change, program registration or program execution after the spot welding sequence is complete.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P6500 Cannot generate working line direction. This error occurs when weld start and end points are the same, and motion direction cannot be determined. ⇒ Ensure the start and end points are not the same. _____________________________________________________________________ ERROR CODE P6501 Illegal tool posture.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE P7000 Cannot program reset, because not at home position 1. The robot is not at the registered home 1 position, and the program reset signal is ignored. ⇒ Ensure the robot is at the home 1 position, and re-execute.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.3.2.4 WXXXX MECHANICAL/CONTROL WARNING ERROR CODES ERROR CODE W1000 Cannot move along straight line JTXX in this configuration. When operating manually in teach mode and in base or tool mode, axis (JTXX) speed exceeds capability with the wrist in this posture. ⇒ Change the wrist posture. ⇒ Reduce teach speed. ⇒ Reduce repeat speed. ⇒ Change the interpolation mode to joint.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W1005 Illegal center of gravity, default parameter is set. Load mass value is set to a value other than zero, but the center of gravity is set to all zeroes. ⇒ Enter the correct center of gravity value. _____________________________________________________________________ ERROR CODE W1006 Incorrect load moment. Default parameter is set.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W1010 RAM battery low voltage. Main causes include: 1. Backup battery voltage below minimum value (3.3 VDC or less). 2. Defective battery harness. 3. Defective 1KA board. ⇒ Back up system and program data. Check and replace batteries as required. ⇒ Check batteries for defective connections. Repair as required. ⇒ Defective battery voltage monitoring circuit. Replace the 1KA board.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W1013 Encoder battery low voltage [Servo (XX)]. Voltage of the encoder back up battery on the 1FG/1HG board decreased to 3.3 volts or less, or the encoder battery alarm signal (BAL_AL) is disconnected. This error is only detected at control power on or motor power on.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W1015 Possibility of failure. The monitored value of I2 (current squared) exceeds the normal value for the monitored program and indicates excessive wear in the cyclo reduction unit or a servo motor/brake problem. Current increase may be caused by program modifications. ⇒ If the robot control program is modified, the monitored value of I2 may need to be reevaluated and changed.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W1018 Network parameter is changed. Turn OFF & ON the control power. When network setting data is changed, the controller power must be cycled OFF and ON. ⇒ Cycle controller power OFF and ON. _____________________________________________________________________ ERROR CODE W1019 The registered value is beyond rated load.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W4501 FIELD-BUS) Master port OFFLINE. Master port is offline due to communication line termination. ⇒ Check the slave and communication line and repair as necessary. When repairs are completed wait for on-line status to return (1JF board LED 1 ON). _____________________________________________________________________ ERROR CODE W5001 PLC communication error.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W5004 Weld controller XX response error. During communication with the weld controller, data received from the weld controller does not conform to the specified protocol. ⇒ Ensure the welder connection is established. Repair or replace weld controller and interface cable as necessary. ⇒ Ensure the welder is operational. ⇒ Check for noise malfunction and shield integrity.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W5007 (Spot welding) Weld fault XX. This error occurs when a weld complete signal is not received by the robot controller from the remote weld controller (RWC), or there is an electrical malfunction with the RWC.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING ERROR CODE W5010 (Spot welding) Main cable exchange alarm XX. The present value of the counter for the specified weld gun exceeds the set value for initiating an alarm to replace the main cable (XX indicates gun number). ⇒ Reset the alarm counter value. ⇒ Replace the main cable. ⇒ Select a higher counter value.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.4 TROUBLESHOOTING FLOWCHARTS The following flowcharts are arranged by error code number. Refer also to the corresponding error code information in section 1.3.2.2 during troubleshooting procedures.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1029 Does this error occur just after resetting error E1035, E1036, or E1037? Yes Follow troubleshooting flowchart for each error No Replace encoder Yes Does problem still exist? No END Yes Replace 1KB board Does problem still exist? No END Yes Check connections at the encoder connector Check connections on the 1FG/1HG board Check connections in the separation harness Check connections, jumpers, and sw
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Does problem still exist? No END Yes Check inside machine harness and separation harness Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Service call Figure 1-6 Error E1029 Flowchart (2) 1-212 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1032 Does this error occur just after resetting error E1035, E1036, or E1037? Follow troubleshooting flowchart for each error Yes No No Replace encoder END Yes Does problem still exist? Yes Replace 1KB board Does problem still exist? No END Yes Check connections at the encoder connector Check connections on the 1FG/1HG board Check connections in the separation harness Check connections, jumpers, and sw
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Does problem still exist? No END Yes Check inside machine harness and separation harness Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Service call Figure 1-8 Error E1032 Flowchart (2) 1-214 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1034 Does the encoder revolve over 300 RPM? (For conveyor encoder) Reduce conveyor encoder revolution speed under 300 RPM at power-up Yes No END Check connections at the encoder connector Check connections on the 1FG/1HG board Check connections in the separation harness Check connections, jumpers, and switches on the 1KB board Does problem still exist? No END Yes Replace encoder Does problem still exis
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Replace 1KB board Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Check machine harness and separation harness Does problem still exist? No END Yes Service call Figure 1-10 Error E1034 Flowchart (2) 1-216 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1035 Retry robot program execution or manual operation carefully Yes Can you reset the error? No Yes Check connections at the encoder connector Does the error reoccur? No Check connections on the 1FG/1HG board END Check connections in the separation harness Check connections, jumpers, and switches on the 1KB board Does problem still exist? No END Yes Replace encoder Does problem still exist? No EN
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Replace 1KB board Does problem still exist? No END Yes Check machine harness and separation harness Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Service call Figure 1-12 Error E1035 Flowchart (2) 1-218 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1036 Retry robot program execution or manual operation carefully Yes Can you reset the error? No Yes Check connections at the encoder connector Does the error reoccur? No Check connections on the 1FG/1HG board END Check connections in the separation harness Check connections, jumpers, and switches on the 1KB board Does problem still exist? No END Yes Replace encoder Does problem still exist? No EN
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Replace 1KB board Does problem still exist? No END Yes Check machine harness and separation harness Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Service call Figure 1-14 Error E1036 Flowchart (2) 1-220 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1037 Retry robot program execution or manual operation carefully Yes Can you reset the error? No Yes Replace encoder Does the error reoccur? Yes No Does problem still exist? No END Yes Replace 1KB board Does problem still exist? No END Yes Check connections at the encoder connector Check connections on the 1FG/1HG board Check connections in the separation harness Check connections, jumpers, and swit
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Does problem still exist? No END Yes Check inside machine harness and separation harness Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Service call Figure 1-16 Error E1037 Flowchart (2) 1-222 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1038 Replace encoder Does problem still exist? No END Yes Replace 1KB board Does problem still exist? No END Yes Check connections at the encoder connector Check connections on the 1FG/1HG board Check connections in the separation harness Check connections, jumpers, and switches on the 1KB board Does problem still exist? No END Yes A Figure 1-17 Error E1038 Flowchart (1) August 9, 2005 1-223
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Check inside machine harness and separation harness Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Service call Figure 1-18 Error E1038 Flowchart (2) 1-224 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Error E1039 Replace encoder Does problem still exist? No END Yes Replace 1KB board Does problem still exist? No END Yes Check connections at the encoder connector Check connections on the 1FG/1HG board Check connections in the separation harness Check connections, jumpers, and switches on the 1KB board Does problem still exist? No END Yes A Figure 1-19 Error E1039 Flowchart (1) August 9, 2005 1-225
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak TROUBLESHOOTING A Does problem still exist? No END Yes Check inside machine harness and separation harness Does problem still exist? No END Yes Replace 1FG/1HG board Does problem still exist? No END Yes Service call Figure 1-20 Error E1039 Flowchart (2) 1-226 August 9, 2005
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2.0 COMPONENT REPLACEMENT This chapter describes replacement procedure for parts inside the controller: printed boards, power blocks, hardware including AVR, etc., and, units. 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.4 2.4.1 2.4.2 2.5 2.6 2.6.1 2.6.2 2.6.2.1 2.6.2.2 2.6.3 2.7 2.7.1 2.7.2 2.7.3 2.8 2.8.1 2.8.2 2.9 2.9.1 2.9.2 2.
Kawasak 2.1 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT GENERAL SAFETY PRECAUTIONS ON REPLACEMENT This section describes the precautions to be taken when replacing parts due to trouble, etc. This information is presented here for use as general precautions. In addition to these, adhere the safety measures required for each replacement procedure.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 7. Use only Kawasaki approved parts during replacement. 8. When replacing printed boards, do not fail to turn OFF control power. To replace power block, MC unit, or AVR, wait at least seven minutes after control power OFF before removing connectors. Then confirm that output voltage from the DC power source and the P-N voltage are 0V. 9.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 18. Printed boards and power blocks are designed differently for each robot model. to replace the correct type. Be sure 19. When air or water is supplied, shut OFF the supply source and purge any remaining pressure from the lines before starting any replacement procedure. 20. Use lighting of 1500 lux or more to avoid mistakes when reading data or replacing defective parts. 21.
Kawasak 2.2.1 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1KA BOARD (USER I/F BOARD) 1. This is the user I/F board used for storing taught pose data, user program data, etc. in memory. Before replacing the board, be sure to save all data to storage media such as PCCARD, FDD, etc. For more details about data saving procedures, refer to the Operation Manual, a separate volume. 2. After completion of data saving, turn OFF the control power. 3.
D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT Buttons of the ejector CN8 1KN/1QN board Battery SW2 CN11 Battery connector SW1 CN6 CN7 CN9 CN2 CN3 IP board 1KJ/1QJ board 1KK board CN5 CN4 CN10 Overview of the 1KA board 2.2.2 1KB BOARD (ARM CONTROL BOARD) 1. Turn OFF the control power. 2. Press the red button on the ejector of the 1KB board to release the lock, and pull out the 1KB from the card rack by extending the ejector up and down. 3.
Kawasak 2.2.3 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1KP BOARD (POWER SEQUENCE BOARD) 1. Turn OFF the control power. 2. Loosen the screws on top and bottom of the 1KP board, and pull out the 1KP from the card rack by holding the ejectors at both ends of the board. If wired to the front connector, remove the connector first. 3. Confirm that settings for SW, J1 and J2 on the new 1KP are the same as before board replacement.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 6. Confirm the voltage at each check pin on the 1KA and 1KP as shown below. 1KA board No. TP2 TP3 TP4 Color Standard Yellow −12.0 V Yellow +12.0 V Yellow +5.0 V TP6 Yellow +3.3 V 1KP board No. Color TP1 White Standard +24.0 V Allowable range −11.95 V∼ −12.05 V +11.95 V∼ +12.05 V +4.95 V∼ +5.05 V +3.16 V∼ +3.44 V Allowable range +23.9 V∼ +24.7 V If the voltage is out of allowable range, Adjust the volume on the AVR.
Kawasak 2.2.5 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1NR BOARD (BRAKE CONTROL BOARD) 1. Turn OFF the control power. 2. Loosen the screws on top and bottom of the 1NR board, and pull out the 1NR from the card rack by holding the ejectors at both ends of the board. If wired to the front connector, remove the connector first. 3. Confirm that settings for J1, J2 and J3 on the new 1NR are the same as before board replacement.
Kawasak 2.3 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR POWER BLOCK UNIT This section describes the replacement procedure for the power block unit mounted in the controller. Four types of power block are available as described below. 1. 1KC: Power block for large robot (six axes) 2. 1KD: Power block for small robot (six axes) 3. 1KL: Optional power block for large motor (single axis) 4.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1. Remove all connectors connected to the power block unit. 2. Loosen the four screws fixing the power block unit to the controller so that the power block unit can be removed from the controller. (These screws are not removed from the power block unit.) 3. To remove the power block unit, pull it out by sliding on the fulcrum. handle on top with one hand. To be safe, hold the 4.
D SERIES CONTROLLER Kawasak 2.3.3 TROUBLESHOOTING AND COMPONENT REPLACEMENT 1KD POWER BLOCK UNIT (FOR D7X CONTROLLER) ！ DANGER Before starting replacement work, turn OFF the control power and wait at least seven minutes. 1. Remove the controller cover. 2. Remove the connectors X506 and X507 connected to the power block unit. 3. Remove the screw fixing the earth wired from the power block unit. 4. Remove the four screws fixing the power block unit to the controller. 5.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT X302 X311 Fixing screws (two in upper corners) Fixing screws (two in lower corners) 2-13
Kawasak 2.3.4 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1KL POWER BLOCK UNIT ！ DANGER Before starting replacement work, turn OFF the control power and wait at least seven minutes. 1. Remove all connectors connected to the power block unit. 2. Loosen the four screws fixing the power block unit to the controller (1 to 4 in figure below) so that the power block unit can be removed from the controller. (These screws are not removed from the power block unit.) 3.
Kawasak 2.4 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR MC UNIT PARTS (FOR D3X CONTROLLER) This section describes the replacement procedure for the MC unit (power supply unit) and the 1KQ board (power circuit board) which flanks the MC unit. 2.4.1 MC UNIT ！ DANGER Before starting replacement work, turn OFF the control power and wait at least seven minutes. 1.
D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT ！ CAUTION MC unit weighs approx. 6kg. Be careful not to cut or squeeze the tips of your fingers when replacing MC unit. 2.4.2 1KQ BOARD (POWER CIRCUIT BOARD) ！ DANGER Before starting replacement work, turn OFF the control power and wait at least seven minutes. 1. Remove the MC unit. For details, refer to 2.4.1 MC Unit. 2.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 4. Loosen the five nuts fixing the 1KQ to the plate (1 to 5 in figure below), and remove the 1KQ. 5. Attach the new 1KQ to the plate with the five nuts removed in step 4. 6. Restore the connector and two wires removed in step 3 to the assy assembled in step 5. 7. Refasten the screws and connect the connector removed in step 2. 8. Attach the MC unit to the controller. Plate For details, refer to 2.4.1 MC Unit.
Kawasak 2.5 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR 1NQ BOARD (FOR D7X CONTROLLER) This section describes the replacement procedure for the 1NQ board (power circuit board) 1. Turn OFF the control power. 2. Remove the power block unit. D7x Controller).) (For the procedure, see 2.3.3 1KD Power Block Unit (for 3. Remove the 1NR, 1KP, 1KB, and 1KA boards in the card rack. 4. Remove all connectors connected to the 1NQ board. 5.
Kawasak 2.6 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR FAN (FOR D3X CONTROLLER) Fans are installed for the card rack, the power block unit, and the MC unit. describes the replacement procedure for these fans. 2.6.1 This section FAN FOR CARD RACK 1. Turn OFF the control power. 2. Remove the connector connecting the fan to the card rack. two screws fixing the fan unit. Then, loosen and remove the 3.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT FANS ON THE BACK OF CONTROLLER 2.6.2 This section describes the replacement procedures for the two fans mounted on the controller back. The upper fan cannot be seen from outside. 2.6.2.1 UPPER FAN ON BACK OF CONTROLLER 1. Turn OFF the control power. 2. Remove the six screws fixing the plate on the controller back (1 to 6 in figure below). 3. Pull out the plate, remove the connector connected to the controller, then remove the plate.
Kawasak D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2.6.2.2 LOWER FAN ON BACK OF CONTROLLER 1. Turn OFF the control power. 2. Remove the six screws fixing the plate on the controller back. 3. Pull out the plate, remove the connector connected to the controller, and remove the plate. 4. Remove the power line and the earth wire connected to the fan. Loosen and remove the four screws fixing the fan, and then remove the fan. 5.
Kawasak 2.6.3 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT MC UNIT FAN 1. Turn OFF the control power. 2. Remove the two screws at the bottom of the MC unit (1 and 2 in figure below) and pull out the plate. Remove the connecter connected to the 1KQ board and remove the fan unit. 3. Remove the four screws fixing the fan and remove the fan. 4. Attach the new fan to the plate with the four screws. wind blows top to down. Be sure to reattach the fan correctly; 5.
Kawasak 2.7 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR FAN (FOR D7X CONTROLLER) Fans are installed for the card rack, the power block unit, and the cover (only for D71/74/77 controller). This section describes the replacement procedure for these fans. 2.7.1 FAN FOR CARD RACK 1. Turn OFF the control power. 2. Open the controller cover. 3. Remove the four screws fixing the fan. 4.
D SERIES CONTROLLER Kawasak 2.7.2 TROUBLESHOOTING AND COMPONENT REPLACEMENT FAN FOR POWER BLOCK UNIT 1. Turn OFF the control power. 2. Remove the four screws fixing the cover on the controller back, and then remove the cover. 3. Remove the four screws fixing the fan. 4. Remove the power line and the earth wire connected to the fan, and then remove the fan. 5. Restore the power line and earth wire removed in step 4 to the new fan. 6. Fix the fan with the four screws.
Kawasak 2.7.3 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT HEAT EXCHANGE FAN (FOR D71/74/77 CONTROLLER) Heat exchange fan is installed on the left side of the controller cover. 1. Turn OFF the control power. 2. Remove the controller cover. 3. Remove the power harness from the bands which fix the harness. 4. Remove the four screws fixing the fan, and then remove the fan. 5. Attach the new fan with the four screws. Be sure to reattach the fan correctly. 6.
D SERIES CONTROLLER Kawasak 2.8 TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR BATTERIES This section describes the replacement procedure for the battery provided to backup data. 2.8.1 BATTERY ON 1KA BOARD As backup power supply for SRAM and RTC (Real Time Clock), the 1KA board is equipped with a lithium battery and an emergency super capacitor for use during battery replacement.
Kawasak 2.8.2 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT BATTERY ON 1FG/1HG BOARD 1. Record the encoder value for all axes before replacing a battery. 2. Before replacing the battery, confirm that the new battery has +3.6V or more voltage. 3. Turn OFF the control power. 4. For the 1HG board, pull out the connector box located on the base of the robot main body. For the 1FG board, remove the plate that is installed with a battery. 5.
Kawasak 2.9 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR FUSES This section describes the replacement procedure for the fuses. 2.9.1 FUSES ON 1KP BOARD Two types of fuses- Fuse1 and Fuse2- are mounted on the 1KP board. 1. Turn OFF the control power. 2. Push the fuse on the front of the board and turn it 90 degrees to the left. and remove the fuse from the board. Then pull it out 3. Push in the new fuse, and turn it 90 degrees to the right to install.
Kawasak 2.9.2 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT FUSES ON 1NQ BOARD (FOR D7X CONTROLLER) 1. Turn OFF the control power. 2. Remove the controller cover. 3. Turn the fuse 90 degrees to the left. Then pull it out and remove the fuse from the board. 4. Push in the new fuse, and turn it 90 degrees to the right to install. 5. Restore the controller cover.
Kawasak 2.10 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT REPLACEMENT PROCEDURE FOR FILTER Wash filters periodically to keep them clean. procedure described below. For replacement, follow the replacement Filters are located on the side and back of the controller. these filters. Take the same procedure to replace 1. In the center, bottom of the holder for the filter there is a notch. Insert something tube shaped into the notch, and push up the filter.
