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D SERIES CONTROLLER
TROUBLESHOOTING AND
COMPONENT REPLACEMENT
MPVDCONTV113E-3
Kawasak
Kawasaki Robotics (USA), Inc.
Kawa ak
s
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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. Co
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D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Kawasak REVISION HISTORY Revision Release NumberDe ateDs escription of Chang Initial -3 01y 1/20/0IB nitial PDF release, based on Rev.-0 of print cop CB/C -4 14y /27/0RB evision 1, based on Rev.-1 of print cop CB/C -5 39y /06/0RB evision 3, based on Rev.-3 of print cop CB/C
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.0 TROUBLESHOOTING................................................................................... 1-2 1.1 Error Recovery ............................................................................................... 1-2 1.2 Preliminary Troubleshooting ........................................................................... 1-5 1.2.1 Troubleshooting Common Failures.......................................
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D SERIES CONTROLLER Kawasak 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.
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Locate error on the error Source of error known Troubleshoot table and determine the Run Program and correct characteristics and possible and continue source of causes of the error to monitor error Source of error unknown Error cleared and robot Run Program Press the yellow runs normally and continue reset button on the to monitor controller panel Error will not clear or machine is in a “locked” mode Have any c
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING Continued from previous pg Error still present Remove the 1KA board from the rack and allow RAM memory to deplete Reinstall Error clears and robot Run program 1KA board, runs normally and continue initialize the to monitor system, zero Begin electrical troubleshooting and repair if qualified; call service technician for further assistance Figure 1-2 Troubleshooting Process (Continued) 1-4 August 9, 2005
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT TROUBLESHOOTING 1.2 PRELIMINARY TROUBLESHOOTING Prior to following error code troubleshooting procedures, ensure preliminary trouble- shooting 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. Ensure proper +5 VDC, +12 VDC, -12 VDC and +24 VDC are ava
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D SERIES CONTROLLER Kawasak 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. Defective F1
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D SERIES CONTROLLER Kawasak 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. Ensure the power connector at the AVR p
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D SERIES CONTROLLER Kawasak 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. Main
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D SERIES CONTROLLER Kawasak 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. ⇒ Ensure th
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT 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. Disconnected or short-circuited motor powe
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D SERIES CONTROLLER Kawasak 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. Rob
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT 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 spec
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D SERIES CONTROLLER Kawasak 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 mes- sage area and other error messages are shown in a pop-up screen display (Figure 1-4). Step Program [Comment ] PC Status 03-01-31 11:55 JOINT 1 pcprg1 T p6 g 1 C [ ]
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT 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. PC Error Display Example: Error (D0001) CPU error Code=1 Task (Pc01) Stop SIG=00070004 [FAULT (PARALLEL)] PC=***** Indicates the place the error occurred ⇒ Refer to the err
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D SERIES CONTROLLER Kawasak 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. PC Error Display Example: Error (D0003) VME bus error Code=1 Task (Pc01) Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=***** bus-read=******** bus-write=******
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D SERIES CONTROLLER Kawasak TROUBLESHOOTING AND COMPONENT REPLACEMENT 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 soft- ware, defective 1KB board, or noise related malfunction. PC Error Display Example: Error (D0005) [ARM CONTROL BOARD] CPU BUS error Code=1 Task (Pc01) Stop SIG=00070004 [NMI(VME B
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D SERIES CONTROLLER Kawasak 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. The addressing of the FCHK com
