Kawasaki MPVDCONTV113E-3 User Manual
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Kawasaki Robotics (USA), Inc.
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D SERIES CONTROLLER
TROUBLESHOOTING AND
COMPONENT REPLACEMENT
MPVDCONTV113E-3
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.
Copyright © 2001, Kawasaki Robotics (USA), Inc.
Wixom, Michigan 48393
The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discontinue specific robot models and associated hardware and software, designs, descriptions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.
This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.
KAWASAKI ROBOTICS (USA), INC. TRAINING
Training courses covering operation, programming, electrical maintenance, and mechanical maintenance are available from Kawasaki Robotics (USA), Inc. These courses
are conducted at our training facility in Wixom, Michigan, or on-site at the customer’s
location.
For additional information contact:
Kawasaki Robotics (USA), Inc.
Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
TROUBLESHOOTING AND COMPONENT REPLACEMENT
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REVISION HISTORY
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D SERIES CONTROLLER
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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 ................................................................. 1-5
1.2.1.1 Controller Power Cannot Be Set to ON .......................................................... 1-6
1.2.1.2 Teach Pendant Is Inoperable ......................................................................... 1-8
1.2.1.3 Motor Power Cannot Be Enabled ................................................................. 1-10
1.2.1.4 Robot Does Not Move.................................................................................. 1-11
1.3 Error Codes ................................................................................................. 1-12
1.3.1 Error Display ................................................................................................ 1-13
1.3.2 Error List ...................................................................................................... 1-13
1.3.2.1 DXXXX Fatal Error Codes............................................................................ 1-14
1.3.2.2 EXXXX Non-Fatal Error Codes .................................................................... 1-59
1.3.2.3 PXXXX Operation Error Codes .................................................................. 1-159
1.3.2.4 WXXXX Mechanical/Control Warning Error Codes .................................... 1-200
1.4 Troubleshooting Flowcharts ....................................................................... 1-210
1-1August 9, 2005
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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. Troubleshooting should begin with confirmation of basic integrity of
the system: ensure that the power supply is on and meeting supply requirements, all
cables are correctly attached, all circuit boards are properly installed and fully seated, all
peripheral equipment is wired correctly, software is properly configured, etc.
1-2 August 9, 2005
TROUBLESHOOTING AND COMPONENT REPLACEMENT
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Source of error known
Locate error on the error
table and determine the
characteristics and possible
causes of the error
Source of error unknown
Press the yellow
reset button on the
controller panel
Error will not clear or
machine is in a “locked” mode
Error cleared and robot
runs normally
Error clears and robot
runs normally
to monitor
and continue
Run Program
Run Program
and continue
to monitor
Troubleshoot
and correct
source of
error
Ye s
Ensure the robot
system data, all
components, signals,
and programs are
compatible
agrees with program, etc.
removed, signal interface
components added or
internal parts, interface
made to system? New
beenchangesanyHave
No
Cycle the
controller power
OFF and ON
Run Program
and continue
to monitor
Error or “locked”
condition cleared
Error still present
Continued on next page
to monitor
and continue
Run Program
Create
backup information
files and initialize the
system
Run program
and continue
to monitor
Error or “locked”
condition cleared
Reset
system settings not
set to defaults after
initialization
TROUBLESHOOTING
D SERIES CONTROLLER
Figure 1-1 Troubleshooting Process
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TROUBLESHOOTING AND COMPONENT REPLACEMENT
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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
TROUBLESHOOTING
D SERIES CONTROLLER
Figure 1-2 Troubleshooting Process (Continued)
1-4 August 9, 2005
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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
3. Ensure proper +5 VDC, +12 VDC, -12 VDC and +24 VDC are available from the
AVR power supply.
4. Observe the state of LEDs and refer to the appropriate section of the
Controller Electrical Maintenance Manual
these conditions are
5. Check for loose connection at circuits boards and cable connections.
6. Ensure all circuit boards are properly seated in the card rack (where applicable).
7. Ensure the F1 and F2 fuses on the 1KP board are
1.2.1 TROUBLESHOOTING COMMON FAILURES
This section describes some common failures, possible causes, and corrective actions.
1.2.1.1 Controller Power Cannot Be Set ON
not normal, correct the cause of abnormal LED indications.
for conditions indicated by the LEDs. If
not tripped.
D Series
not open.
1.2.1.2 Teach Pendant is Inoperable
1.2.1.3 Motor Power Cannot Be Set ON
1.2.1.4 Robot Does Not Move
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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 circuit breaker.
⇒
Interrupt the 460 VAC to the main disconnect (circuit breaker F1) set the controller
main disconnect to ON. Using an ohm meter check for a short circuit between these
points:
R and S, S and T, T and R, R and FG, S and FG, T and FG (FG=frame ground)
If a short circuit is detected replace components as necessary (wiring, transformer
T1, circuit breaker F1, etc.).
Failure 2: When the main disconnect is set to ON, the control power lamp does not
illuminate (circuit breaker F1 does not trip).
This failure occurs when the controller does not activate properly because of an abnormality in the primary power supplied to the controller or in the power supply circuit in the
controller.
Main causes include:
1. The primary power voltage supplied to the controller is not within specifications, the
primary power cable is disconnected or damaged, or the primary power is not
supplied.
2. Power is not supplied to the 1KQ/1NR board, or the 1KQ/1NR board is defective.
3. Power is not supplied to the AVR power supply.
4. Power is not supplied to the control power lamp due to a defective AVR power
supply, 1KX/1NR board, 1LS/1NS board or control power lamp.
5. Disconnected or short-circuited wiring in the controller.
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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 power supply is properly connected and not damaged.
⇒
Ensure to output voltages from the AVR power supply are within specifications.
⇒
Ensure the control power lamp is properly installed and is not defective.
⇒
Repair or replace disconnected or short-circuited wiring in the controller.
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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 causes include:
1. +12 VDC is not supplied to the teach pendant.
2. Defective LCD panel, circuit board, or other internal teach pendant components.
3. Disconnected or short-circuited teach pendant cable.
⇒
Ensure the teach pendant cable is properly connected to the controller.
⇒
Replace the teach pendant.
⇒
Replace the teach pendant cable.
Failure 2: The back light is illuminated, but the screen is not displayed.
When the teach pendant back light is illuminated this indicates power is supplied to the
teach pendant. If the teach pendant is operating normally the initial screen is displayed
regardless of the 1KA board condition.
Main causes include:
1. Defective LCD panel, circuit board, or other internal teach pendant components.
⇒
Replace the teach pendant.
Failure 3: The teach pendant screen is displayed and the back light is illuminated, but
key input and AS Language commands are not possible.
This condition occurs when key input and AS Language commands do not reach the
1KA board or data from the 1KA board does not reach the teach pendant.
Data is transmitted between the 1KA board and the teach pendant as shown in figure 1-
3.
1-8 August 9, 2005
TROUBLESHOOTING AND COMPONENT REPLACEMENT
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1KX/1NX Mother Board
1KA Main CPU Board
Display Device
Teach Pendant
Input
Keys
TROUBLESHOOTING
D SERIES CONTROLLER
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 the teach pendant cable is properly connected to the controller.
⇒
Replace the teach pendant cable.
⇒
Replace the teach pendant.
⇒
Replace the 1KA or 1KX/1NX boards.
Figure 1-3 1KA/Teach Pendant Communication
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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 power supply harness.
6. Motor temperature or controller internal temperature exceeds limits
⇒
If the operation panel error lamp is illuminated or an error message is displayed on
the teach pendant LCD, take appropriate measures to release the error condition
according to the error message.
⇒
Check and repair any abnormalities in the motor power supply circuit.
⇒
Ensure all EMERGENCY STOP switches are released.
⇒
Replace the power block.
⇒
Replace the motor power supply harness.
⇒
Ensure motor temperature and controller internal temperature does not exceed limits.
1-10 August 9, 2005
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! WARNING
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. Robot is waiting for input signals in repeat mode (cycle start, step forward, program
change, WX, JUMP, etc.)
⇒
Release external hold condition.
⇒
If the operation panel error lamp is illuminated or an error message is displayed on
the teach pendant LCD, take appropriate measures to release the error condition
according to the error message.
⇒
Ensure the operation panel switches are set correctly for robot operation.
⇒
Ensure proper brake voltage is available to the brake release circuit. Check and
repair poor connections, disconnected connectors, open wiring, short circuited wiring,
or any abnormalities in the brake circuits. Ensure the 1KP board, 1KQ/1NR board,
AVR power supply, MC unit, 1KQ/1NR board, servo motor, and controller internal
brake harnesses are in serviceable condition.
⇒
When check mode is selected, ensure an enabling device is engaged and the GO
(step forward) key is pressed.
⇒
In repeat mode, ensure input signals are received to release a wait condition.
The robot may move suddenly when a wait condition is
released. Do not approach the robot when it appears to
be stopped.
1-11August 9, 2005
D SERIES CONTROLLER
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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 specific error. Troubleshooting
information is preceded by an ⇒
symbol.
Table 1-1 provides an explanation of the error code prefixes.
Table 1-1 Error Code Prefix Descriptions
Table 1-2 describes the controller state for each type of error.
Table 1-2 Controller Error State
1-12 August 9, 2005
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Pro ramg
[Comment ]
Step
PC
Status
03-01-31 11:55
90%
RPS
Pro ram aborted. No = 1g
Error
p6g
[
1
[
]
0.000 0.000 0.000 0.000 0.000 0.000
JT 1 JT 2 JT 3 JT 4 JT 5 JT 6
(E0100) 02-11-08(Fri) 16:33:20
Abnormal comment statement exists.
T
C
R
]
!
1 pcpr 1g
Reset
Close
JOINT
System Message Area
Error Pop-up Screen
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).
1.3.2 ERROR LIST
Refer to the following sections for errors and descriptions:
1.3.2.1 DXXXX Fatal Error Codes
1.3.2.2 EXXXX Non-Fatal Error Codes
1.3.2.3 PXXXX Operation Error Codes
1.3.2.4 WXXXX Mechanical/Control Warning Error Codes
Figure 1-4 Teach Pendant Error Screen Display
1-13August 9, 2005
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PC Error Display Example:
Error (D0001) CPU error Code=1
Task (Pc01) Stop SIG=00070004 [FAULT (PARALLEL)] PC=*****
Indicates the place the error occurred
PC Error Display Example:
Error (D0002) CPU BUS error Code=1
Task (Pc01) Stop SIG=00070004 [NMI ] PC=*****(VME BUS ERROR)
Indicates the place the error occurred
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.
⇒
Refer to the error message displayed on a PC interfaced with the controller.
⇒
Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒
If the error does not reset when power is cycled, initialize the system and reload
program data.
⇒
Replace the 1KA board.
⇒
If the above steps do not correct the error, contact KRI customer service
_____________________________________________________________________
.
ERROR CODE D0002 Main CPU BUS error. (PC=XX)
A 1KA board 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 1KA board, or noise related malfunction.
⇒
Refer to the error message displayed on a PC interfaced with the controller.
⇒
Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒
If the error does not reset when power is cycled, initialize the system and reload
program data.
⇒
Replace the 1KA board.
⇒
If the above steps do not correct the error, contact KRI customer service
_____________________________________________________________________
.
1-14 August 9, 2005
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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=******** *********
Indicates the place the error occurred
PC Error Display Example:
Error (D0004) [ARM CONTROL BOARD] CPU error Code=1
Task (Pc01) Stop SIG=00070004 [FAULT (PARALLEL)] PC=*****
Indicates the place the error occurred
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.
⇒
Refer to the error message displayed on a PC interfaced with the controller.
⇒
Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒
If the error does not reset when power is cycled, initialize the system and reload
program data.
⇒
Replace the 1KA board.
⇒
If the above steps do not correct the error, contact KRI customer service
_____________________________________________________________________
.
ERROR CODE D0004 [ARM CONTROL BOARD] CPU error. (PC=XX)
The 1KB board CPU is stopped (detected by the AS software). This error is caused by
defective AS or servo software, defective hardware, or noise related malfunction.
⇒
Refer to the error message displayed on a PC interfaced with the controller.
⇒
Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒
Ensure the correct 1KB board software is loaded into the 1KA board.
⇒
Replace the 1KB board.
⇒
If the above steps do not correct the error, contact KRI customer service
_____________________________________________________________________
.
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PC Error Display Example:
Error (D0005) [ARM CONTROL BOARD] CPU BUS error Code=1
Task (Pc01) Stop SIG=00070004 [NMI( )] PC=*****VME BUS ERROR
Indicates the place the error occurred
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 software, defective 1KB board, or noise related malfunction.
⇒
Refer to the error message displayed on a PC interfaced with the controller.
⇒
Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒
Ensure the correct 1KB board software is loaded into the 1KA board.
⇒
Replace the 1KB board.
⇒
If the above steps do not correct the error, contact KRI customer service
_____________________________________________________________________
.
ERROR CODE D0900 Teach data is broken.
The program storage area of the system memory is damaged and is not linking data
correctly.
Main causes include:
1. Loss of memory battery back-up.
2. Noise related malfunction.
3. Defective 1KA board.
⇒
Set the 1KA board switch SW2-8 to ON and initialize the memory, do not use AUX
0805 or SYSINIT command. Reload the robot program data.
⇒
Check the memory backup battery. Replace if necessary (3.3 VDC or less). When
battery voltage drops to 3.3 VDC, or less, error W1010 is displayed.
⇒
Replace the 1KA board if the error recurs.
_____________________________________________________________________
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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 command is wrong.
3. The flash memory and 1KA board are defective.
4. The system data in the flash memory is corrupt.
⇒
Confirm the content of the command as_load.cmd file on the PC card. If error occurs
immediately after downloading the AS software, download AS software again. If error
continues after download, replace the 1KA board.
_____________________________________________________________________
ERROR CODE D0902 Servo flash memory sum check error.
A check sum error of the servo software in flash memory on the 1KA board occurrs
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 software download.
Main causes include:
1. When the servo software is downloaded, the FCHK command is not executed.
2. The addressing of the FCHK command is wrong.
3. The flash memory and 1KA board are defective.
4. The system data in flash memory is corrupt.
⇒
If the error occurs immediately after servo software download, confirm the content of
sv_load.cmd on the PC card and download servo software again. If the error reoccurs, replace the 1KA board.
_____________________________________________________________________
ERROR CODE D0903 IP board memory error. (Code)
This error occurs when the flash ROM on the 1GS board is corrupt (check sum error).
Code 2: flash ROM SAM error.
Code 3: DPRAM write and read error.
Code 4: SRAM write and read error.
⇒
Replace the 1GS board.
_____________________________________________________________________
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TROUBLESHOOTING AND COMPONENT REPLACEMENT
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.
_____________________________________________________________________
ERROR CODE D1000 Read error of servo control software.
Main causes include:
1. Servo control software (armsc.mb) not found at controller power-up or software is
corrupt.
2. Defective 1KJ/1QJ board.
⇒
Download servo control software (armsc.mb)
Replace 1KJ/1QJ board.
⇒
_____________________________________________________________________
ERROR CODE D1001 Download error of servo control software.
Servo control software (armsc.mb) download failure at controller power-up.
Main causes include:
1. Incorrect servo control software.
2. Defective 1KJ/1QJ board.
2. Defective 1KA and or 1KB board.
⇒
Ensure the correct servo software is loaded into the 1KA board
⇒
Replace the 1KJ/1QJ board.
⇒
Replace the 1KA and or 1KB board.
_____________________________________________________________________
.
.
1-18 August 9, 2005
TROUBLESHOOTING AND COMPONENT REPLACEMENT
K
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TROUBLESHOOTING
ERROR CODE D1002 Init. error of servo software.
D SERIES CONTROLLER
Servo software
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.
⇒
Replace the 1KA and or 1KB boards.
_____________________________________________________________________
ERROR CODE D1003 Init. error of servo control software.
Servo software
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.
(armsc.mb)
(armsv.abs)
initialization failure at controller power-up.
initialization failure at controller power-up.
⇒
Reinstall servo software.
⇒
Check compatibility of AS and servo software and reinstall software as needed.
⇒
Replace the 1KA and or 1KB boards.
_____________________________________________________________________
1-19August 9, 2005
D SERIES CONTROLLER
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Gate Array
ELPD
Servo
Control
CPU
Interface
CPU
1KX (Mother Board)
1KA (Main CPU Board)
1KB (Servo CPU Board)
Watch Dog
Error Signal
Gate Array
ELPD
Servo
Control
CPU
Interface
CPU
1KX (Mother Board)
1KA (Main CPU Board)
1KB (Servo CPU Board)
TROUBLESHOOTING AND COMPONENT REPLACEMENT
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.
⇒
Replace the AS or servo software.
⇒
Replace the 1KA or 1KB board.
_____________________________________________________________________
ERROR CODE D1005 Servo board command error. (xx)
Servo software returned an error code, other than a servo system error, to the AS software after receiving an unrecognized command from the 1KA board.
Main causes include:
1. Corrupt servo or AS software.
2. Noise malfunction.
3. Defective 1KB servo board or 1KA main CPU board.
4. Versions of servo and AS software incompatible.
⇒
Install correct versions of servo and AS software.
⇒
Replace the 1KA or 1KB board.
_____________________________________________________________________
1-20 August 9, 2005
D SERIES CONTROLLER
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Gate Array
ELPD
Servo
Control
CPU
Interface
CPU
1KX (Mother Board)
1KA (Main CPU Board)
1KB (Servo CPU Board)
1KP (Power Sequence Board)
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. The error information from the 1KB board is sent
through the command line and the corresponding error code(s) is/are displayed after
D1006.
⇒
Check the servo error codes that follow this error for additional information. Ensure
that the 1KP board and 1KB board are properly seated.
_____________________________________________________________________
1-21August 9, 2005
D SERIES CONTROLLER
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Regenerative
signal
1KB board
Controller
P-N power
voltage
monitoring
circuit/
Regeneration
controlling
circuit
Drive circuit
1KC: IGBT
1KD: IGBT
1KL/1KR: FET
Regenerative
resistor
Motor power
(P-N power
voltage)
Motor power circuit
Motor power
Power block
Gate Array
Servo
CPU
Interface
CPU
TROUBLESHOOTING AND COMPONENT REPLACEMENT
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. When the
voltage drops to a safe level (365 VDC) the resistor is removed from the circuit.
Main causes include:
1. Abrupt direction changes at high speed.
2. Burned out regenerative resistors in the power block.
3. Defective power block.
4. Defective servo board (1KB board).
5. Loose or disconnected harness between 1KX board (mother board) connector X211
or X212 and the 1KB board (servo CPU board) connector X501 or X502.
6. Defective/incorrect optional second regenerative resistance unit (when used).
⇒
Avoid abrupt high speed direction changes. Change accuracy, speed, add points.
⇒
Replace defective regenerative resistor.
⇒
Install/replace optional second regenerative resistance unit.
⇒
Replace defective 1KB board.
⇒
Replace defective power block.
⇒
Check connections described in item 5 and repair as necessary.
_____________________________________________________________________
1-22 August 9, 2005
D SERIES CONTROLLER
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! WARNING
1KB board
1KP board
P-N power low
voltage error
MC unit
(1KQ/1NQ board)
Primary power
Power block
Gate Array
Servo
CPU
Interface
CPU
P-N power
voltage
monitoring
circuit
Main
disconnect
EPLD
K3 STATUS
Motor power
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.
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.).
Main causes include:
1. Motor power circuit connector detached or loose.
2. Three phase (U, V, W) control power circuit breaker set to OFF.
3. Defective 1KB/1KP/1KQ/1NQ boards.
4. Defective power block.
5. Defective MC unit or harness.
⇒
Ensure the motor power circuit connector is properly attached.
⇒
Ensure control power circuit breaker is set to ON.
⇒
Replace the 1KB/1KP/1KQ /1NQ boards.
⇒
Replace the power block.
⇒
Replace the MC unit or harness.
_____________________________________________________________________
1-23August 9, 2005
D SERIES CONTROLLER
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1KB board
Additional regenerative
resistor (option)
P-N power high
voltage error
MC unit
(1KQ/1NQ board)
Primary power
Power block
Gate Array
Servo
CPU
Interface
CPU
P-N power
voltage
monitoring
circuit
Main
disconnect
Motor power
Regenerative
resistor
Thermal
(140° C)
Additional
regenerative
resistor
Thermal
(140° C)
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.
Main causes include:
1. High inertia loads due to excessive tool weight or incorrect program data.
2. Defective regenerative resistance control circuit, overheat failure of regenerative
resistance unit, defective voltage monitoring circuit, or defective power block.
3. Defective servo board (1KB board) or harness.
4. Defective additional regenerative resistance unit.
⇒
Reteach program steps to eliminate sudden high speed direction changes (dynamic
shock).
⇒
Replace the regenerative unit.
⇒
Replace the 1KB board, power block or harness.
⇒
Replace the additional regenerative resistor unit.
_____________________________________________________________________
1-24 August 9, 2005
D SERIES CONTROLLER
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1KB board
Additional regenerative
resistor (option)
P-N power high
voltage error
MC unit
(1KQ/1NQ board)
Primary power
Power block
Gate Array
Servo
CPU
Interface
CPU
P-N power
voltage
monitoring
circuit
Main
disconnect
Motor power
Regenerative
resistor
Thermal
(140° C)
Additional
regenerative
resistor
Thermal
(140° C)
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). The
thermal switches are wired in series and the AS software cannot distinguish which
thermal switch is activated. For D7X controller, if the heat exchange fan is inoperative
(X207 disconnected) this error is generated.
Main causes include:
1. High inertia loads due to excessive tool weight or incorrect program data.
2. Defective cooling fans.
3. Insufficient clearance for air circulation.
4. High ambient controller temperature.
5. Defective power block.
6. Disconnected or defective harness between the 1KC/1KD board and the additional
regenerative resistor unit.
7. Defective regenerative resistor unit.
8. Defective additional regenerative resistor unit.
9. Defective 1KB board.
10. Disconnected or defective harness between X211 or X212 on the 1KX/1NX board
and X501 or X502 on the power block.
1-25August 9, 2005
D SERIES CONTROLLER
K
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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.
⇒
Connect or repair D7X power supply connection for heat exchange fan (X207).
_____________________________________________________________________
ERROR CODE D1011 AS or servo software is not compatible with the robot
model.
This error occurs when the servo software does not match the robot specifications.
⇒
Load the correct AS and servo software.
_____________________________________________________________________
ERROR CODE D1012 Servo type mismatch. Check the settings.
Servo type set for the robot and servo software do not match.
⇒
Change the robot servo type setting
⇒
Install servo software that matches the robot setting.
_____________________________________________________________________
.
1-26 August 9, 2005
D SERIES CONTROLLER
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1KB board
1KP board
P-N capacitor
discharge error
MC unit
(1KQ/1NQ board)
Primary power
Power block
Gate Array
Servo
CPU
Interface
CPU
P-N power
voltage
monitoring
circuit
Main
disconnect
EPLD
K3 STATUS
Motor power
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.
Main causes include:
1. Defective 1KB/1KP/1KQ/1NQ boards.
2. Defective power block.
3. Defective MC unit or harness between the MC unit and the power block.
⇒
Replace the 1KB/1KP/1KQ/1NQ boards
⇒
Replace the power block.
⇒
Replace the MC unit or harness between the MC unit and the power block.
.
_____________________________________________________________________
ERROR CODE D1014 Servo system error. (Code=XX)
An unrecognized error occurred in the 1KB board.
⇒
Contact KRI customer service (include operating conditions/settings at the time the
error occurred)
_____________________________________________________________________
ERROR CODE D1015 The servo data file does not exist.
.
This error occurs when the servo data file is not found.
⇒
Contact KRI customer service (include operating conditions/settings at the time the
error occurred)
.
_____________________________________________________________________
1-27August 9, 2005
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