Kawasaki MPVDCONTV113E-3 manuals
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Kawasaki MPVDCONTV113E-3 Manual
259 pages 1.49 Mb
REVISION HISTORY 3 Kaaaw sk6 1-3August 9, 2005Figure 1-1 Troubleshooting Process 7 1-4 August 9, 2005Figure 1-2 Troubleshooting Process (Continued) 8 D Series Controller Electrical Maintenance Manual11 Ensure the teach pendant cable is properly connected to the controller.Replace the teach pendant cable. 12 Ensure the teach pendant cable is properly connected to the controller.Replace the teach pendant cable. Replace the 1KA or 1KX/1NX boards. 14 ! WARNING26 ! WARNINGEnsure 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 MC unit or harness. 27 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. 30 Replace the 1KB/1KP/1KQ/1NQ boardsReplace the MC unit or harness between the MC unit and the power block. Contact KRI customer service (include operating conditions/settings at the time the error occurred) 32 Check for disconnection or short circuit in encoder signal line.Replace the encoder or encoder harness. Replace the 1KB servo board. Replace the 1FG/1HG board. Release the servo weld gun axis in teach mode and cycle controller power OFF and ON. 33 Check tool changer connection and repair as necessaryCheck encoder and encoder harness and replace as necessary. Replace the motor, 1KB board, power block, or harness. 34 Ensure the correct AS software is loaded.Replace the 1GM (1KV) board. 35 Check the power line wiring and repair or replace as necessary.36 When the thermal switch opens, error cannot be reset until cooling is complete.Confirm continuity of thermal line. Replace the harness or the 1KB servo board as necessary. Replace the 1KQ/1NR board. 38 It is normal for this error to occur when NFB F1 is set OFF and back ON.Check power supply circuit through NFB F1 and repair as necessary. Check power supply circuit to the AVR through the circuit breaker F3 and repair as Confirm that primary power is supplied according to specifications. Replace the AVR. 39 Check the power supply, machine valve, and the sensor circuits for short circuits.Ensure the 24 VDC load does not exceed the power supply capacity. Check the AVR, the 1KP power sequence board, and the 1KQ/1NQ relay board and 40 Ensure the power supply to the controller is within ratings.Check power supply circuit to the AVR. Confirm the supply power is within specifications. Replace the AVR. 41 Verify the power supply to the controller is within ratings.Check the AVR and NFB F1 and replace as necessary. Confirm supply power is within specifications. 42 Adjust the AVR output voltage.Replace the AVR and each board for the control power supply. Check for short circuits in the operation panel and separation harness and replace as 43 Check for disconnection or short-circuit in the motor harness, and repair or replace as47 Replace the controller/separate/machine harness(es).Replace the LS override switch. Inspect contact points at the safety fence circuit and repair or replace as necessary Check the TEACH/REPEAT switch and relays (RY5 and RY6 on the 1KP board), and 54 Replace the 1KA board.If the error recurs, contact KRI Customer Service Cycle the controller power OFF and ON. Install the appropriate 1KA board and optional 1KN Ethernet board and set the MAC address. 55 Reset error and if error recurs, replace the 1KA/1KB boardsReinstall correct AS software. Replace 1KB board Replace 1KA board Reinstall correct AS software. Reinstall correct 1KB board servo software to the 1KA board. 58 Lower byte 1: install 1LP boardLower byte 3: connect amplifier or motor. Lower byte 2, 4, 5: replace the 1LP board, amplifier or motor. Ensure 1KB board dip switch S8 setting is correct. Ensure correct AS and servo software are installed. Ensure 1KB board dip switch S8 setting is correct. Ensure correct AS and servo software are installed. 63 Ensure all locations used in programs and functions are defined.Define the program or label used with the ON or ONI command. Enter data that is within acceptable range. Rewrite the program to define the array suffix before attempting to process the array. 65 Correct the program to evaluate compatible expressions.Do not enter negative numbers for SQRT function evaluation. Use correct argument values Ensure the range of array suffixes are acceptable. Retype the command using the correct joint number and format. 67 Ensure the correct analog input voltage range is used.Replace PC3JB (TOYOPUC PLC). Replace 1KA board. Replace PC3JB (TOYOPUC PLC). Replace 1KA board. 72 Replace harness.Replace serial flash memory on the 1GV board. Replace 1GV board. Replace 1KP board. Replace harness. Replace 1KP board. 73 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. Check cables and replace as necessary. Reinstall servo software. 75 Reinsert the safety plug.Repair open circuit. 79 Inspect the servo gun and tool changer harnesses; replace if necessary.Replace encoder, replace 1KB board. Check connections at encoder, 1FG/1HG board, and separation harness. Check for continuity in the machine harness and separation harness. Check for noise and shield integrity. Replace 1FG/1HG board. 80 In the case of a conveyor encoder, ensure power-up speed is below 300 RPM.Check connections at encoder, 1FG/1HG board. Replace encoder, replace 1KB, 1KQ/1NR, or 1FG/1HG board. Check for continuity in the machine harness, separation and signal harness repair or 85 Replace encoder, replace 1KB board.Check connections at encoder, 1FG/1HG board, and separation harness. Check for continuity in the machine harness and separation harness. Replace 1FG/1HG board. Inspect the servo gun and tool changer harnesses; replace as necessary. Replace the encoder or encoder harness. Replace signal harness. Replace 1KB board. 88 Ensure spot weld is selected in AUX 0605-1.Teach the start point far enough from the end point so the final end point can be defined Set CHGMOVE to OFF Set the correct axis number for the conveyor ais using the ZCVAXIS command Change to the conveyor tracking mode if the robot does have a traverse unit. Confirm the loaded data is correct. Move the robot inside of the specified area in teach mode. 89 Change the OX signal setting.Modify program data. Ensure the work sensing dedicated signal is set properly. Reteach the start point further away from the workpiece. Repair or replace sensing device or sensing device harness. 95 Correct the time setting to a positive number.Correct program code to evaluate existing values. Check signal number specified in the instruction and ensure it is within system con- figuration. Use signals that have not been dedicated for specific functions. Correct the program data. If RPS is to be used the necessary signals must be dedicated. 98 Specify appropriate modulation instruction.Confirm robot configuration before using the DRIVE or other similar command. 102 Set the accuracy range to a smaller value.Repair or replace sensing device or sensing device harness. Repair the cause of the interruption and reset the error. Insert the ALONE instruction in either the MASTER or the SLAVE robot program. Execute SPINRESET to correct the rotation angle of the JT6 spin axis to stop in 360 degree units. 106 Check the cyclo reduction unit, etc. for mechanical failure. Replace as necessary.Re-teach robot motion as necessary. Check the harnesses and power block unit for electrical malfunctions and replace as Replace the 1KQ/1NR board. Correct the teach data in case of singularity motion. Inspect the workpiece; replace it if necessary. 108 Repair mechanical or electrical failures as necessary.Check interference from external devices. Modify taught wrist positions as required. Ensure the internal interlock circuit is operating normally. Ensure the robot program is written correctly. 115 Replace 1GV/1KA/1KB/1KP boards.Replace controller harness, separate harness, and/or machine harness. Refer to the message displayed after the error message. Refer to the Mitsubishi servo amplifier instruction manual for troubleshooting. Set the alarm and warning to be monitored, and refer to the messaged displayed for troubleshooting. 117 Re-execute parameter download.If this error recurs, contact KRI customer service. Assign an axis number to channel 8 Reset error. If error cannot be reset, cycle controller power OFF and ON. 119 Check the communication cable and replace as necessary.Re-execute the EXECUTE, PCEXECUTE, etc. command. Check the communication cable and replace as necessary. 135 Define the parameters in AUX 1021.Ensure encoder offset data for all guns is the same. Edit the program so that there is only one gun change per step. Select a different gun or disconnect the gun from the other tool changer. 139 Check welder and weld gun repair/replace as necessary.Check 1GS board, and communication cables repair/replace as necessary. 148 Insert an air_cut point in the program before the WORK_DETECT instructionAdd the required air_cut sensing points (two points in this example) 149 Add a reset instruction before the next work instruction150 Reteach points to comply with parameters described above152 Correct weld condition data as necessaryEnsure the workpiece is properly placed Ensure the error check value is set correctly. 162 Enter AS Language command/instruction in correct AS Language syntax.Enter data that is within acceptable range. PC program number must be -1 or 15. Ensure robot number does not exceed the number of robots connected to controller. 164 Ensure correct mode is selected.Ensure correct syntax and format are used. Ensure function is compatible with variables. Use correct syntax and format for functions and arguments. 165 Ensure program names and variables are defined correctly.Use compatible variable type for commands or instructions. Change the previously defined variable name. Enter parentheses in left and right pairs. 166 Enter a binary operator.Enter qualifiers in compliance with AS Language syntax and format. Do not use reserved characters in label identification. Use correct syntax and format for commands and instructions. 167 Use valid switch names.Use system switch names in compliance with AS Language syntax. Use only specified format instructions with TYPE and PRINT commands. Use label names only once per program. Enter program names in compliance with AS Language syntax and format. 168 Use 3 or less dimensions (elements) in an array.Confirm real variable exists. Select new name for array variable. Enter real value array name in compliance with AS Language syntax and format. 169 Use a local variable when defining a temporary argument for a subroutine.Enter the temporary argument in compliance with AS Language syntax and format. Ensure the number of arguments between the source program and the destination program match. Correct the type of the argument in the called program or origin program. 170 Use correct syntax and components in control flow structures, check structure of END statements.171 Limit control flow structure to 10 layers.173 Re-enter the values correctly; timemilitary, dateyy/mm/dd.174 Include the robot number as an argument as required.180 Use instructions and commands that are compatible with the selected mode.To add a function that is not set-up or installed contact KRI customer service Turn TEACH LOCK switch OFF. Ensure steps are copied before paste operation is executed. Ensure insertion point is correct or steps can be overwritten. 183 Install teach pendant and re-execute the T command.Use commands permitted for I/F panel use Set motor power OFF and re-execute Ensure teach mode is selected when executing teach mode functions Use the error cause stored in the error log as a troubleshooting aid Allow the current program execution to complete before re-executing. 190 Ensure that data is within acceptable range.Execute SETTRACE or RESTRACE after logging is completed. Turn off trace functions in all robot and PC programs. Secure the memory address with the SETTRACE command. Use the MNTLOG command or AUX 123-2 to display and confirm the number of maintenance log entries. Make necessary corrections and recalculate value. 191 Do not execute cycle start at a step containing an FN instruction.Insert PC card and re-execute. Replace card battery and re-execute Remove write-protection and re-execute Insert a usable PC card Insert a formatted PC card. Use AUX 0204 to format the SRAM PC card. 193 Replace the 1KA/1KF boardsReplace the harness between the 1KA and 1KF boards. Ensure a valid signal variable is used in the KLogic program Delete unavailable instruction form the KLogic program Check for noise malfunction and shield integrity. 194 Place the basic operation part of the sequence function in HOLD and re-execute.Correct the currently running program using the LSQREWRITE command. Ensure the 1KA board serial flash memory is not set to write-protect Ensure valid signal numbers are used in the KLogic program Replace the 1KA board serial flash memory. 200 Reset the error, and release the wait condition.Manually input the dedicated signal for forced termination of repeat operation Ensure the Confirm that the external axis and gun type data settings are correct. Ensure the new pose data after the shift is within motion range. 202 Ensure the robot is at the home 1 position, and re-execute.204 Enter the correct center of gravity value.Set correct values for the load moment of inertia. 206 Check each harness for short circuit.Replace the encoder, the 1KB servo board, or the 1FG/1HG encoder battery backup board, if necessary. Change the number of axes and initialize the system.214 1-211August 9, 2005Figure 1-5 Error E1029 Flowchart (1) 215 1-212 August 9, 2005Figure 1-6 Error E1029 Flowchart (2) 216 1-213August 9, 2005Figure 1-7 Error E1032 Flowchart (1) 217 1-214 August 9, 2005Figure 1-8 Error E1032 Flowchart (2) 218 1-215August 9, 2005Figure 1-9 Error E1034 Flowchart (1) 219 1-216 August 9, 2005Figure 1-10 Error E1034 Flowchart (2) 220 1-217August 9, 2005Figure 1-11 Error E1035 Flowchart (1) 221 1-218 August 9, 2005Figure 1-12 Error E1035 Flowchart (2) 222 1-219August 9, 2005Figure 1-13 Error E1036 Flowchart (1) 223 1-220 August 9, 2005Figure 1-14 Error E1036 Flowchart (2) 224 1-221August 9, 2005Figure 1-15 Error E1037 Flowchart (1) 225 1-222 August 9, 2005Figure 1-16 Error E1037 Flowchart (2) 226 1-223August 9, 2005Figure 1-17 Error E1038 Flowchart (1) 227 1-224 August 9, 2005Figure 1-18 Error E1038 Flowchart (2) 228 1-225August 9, 2005Figure 1-19 Error E1039 Flowchart (1) 229 1-226 August 9, 2005Figure 1-20 Error E1039 Flowchart (2)
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