Kawasaki MPVDCONTV113E-3

TROUBLESHOOTING

D SERIES CONTROLLER

TROUBLESHOOTING AND COMPONENT REPLACEMENT

1-2 August 9, 2005

Kaaaw sk

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.

Contents

Main Page REVISION HISTORY Kaaaw sk Page Page 1-3August 9, 2005 Source of error known Figure 1-1 Troubleshooting Process 1-4 August 9, 2005 Figure 1-2 Troubleshooting Process (Continued) D Series Controller Electrical Maintenance Manual Page Page Ensure the teach pendant cable is properly connected to the controller. Replace the teach pendant cable. Ensure the teach pendant cable is properly connected to the controller. Replace the teach pendant cable. Replace the 1KA or 1KX/1NX boards. Page ! WARNING Page Page Page Page Page Replace the 1GS board. Page Page Replace the AS or servo software. Replace the 1KA or 1KB board. Install correct versions of servo and AS software. Replace the 1KA or 1KB board. Page 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. ! WARNING 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 MC unit or harness. 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. Page Page Replace the 1KB/1KP/1KQ/1NQ boards Replace 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) Page 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. Check tool changer connection and repair as necessary Check encoder and encoder harness and replace as necessary. Replace the motor, 1KB board, power block, or harness. Ensure the correct AS software is loaded. Replace the 1GM (1KV) board. Check the power line wiring and repair or replace as necessary. 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. Page 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. 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 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. 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. 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 Check for disconnection or short-circuit in the motor harness, and repair or replace as Page Page Page 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 Page Page Page Page Page Page 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. Reset error and if error recurs, replace the 1KA/1KB boards Reinstall correct AS software. Replace 1KB board Replace 1KA board Reinstall correct AS software. Page Page Lower byte 1: install 1LP board Lower 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. Page Page Page Page 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. Page 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. Page Ensure the correct analog input voltage range is used. Replace PC3JB (TOYOPUC PLC). NOTE Replace 1KA board. Replace PC3JB (TOYOPUC PLC). Page Page Page Page Replace harness. Replace serial flash memory on the 1GV board. Replace 1GV board. Replace 1KP board. Replace harness. Replace 1KP board. 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. Page Reinsert the safety plug. Repair open circuit. Page Page Page 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. 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 Page Page Page Page 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. Page Page 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. 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. Page Page Page Page Page 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. Page Page Specify appropriate modulation instruction. Confirm robot configuration before using the DRIVE or other similar command. Page Page Page 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. Page Page Page 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. Page 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. Page Page Page Page Page Page 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. Page 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. Page Check the communication cable and replace as necessary. Re-execute the EXECUTE, PCEXECUTE, etc. command. Check the communication cable and replace as necessary. Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page 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. Page Page Page Check welder and weld gun repair/replace as necessary. Check 1GS board, and communication cables repair/replace as necessary. Page Page Page Page Page Page Page Page Insert an air_cut point in the program before the WORK_DETECT instruction Add the required air_cut sensing points (two points in this example) Add a reset instruction before the next work instruction Reteach points to comply with parameters described above Page Correct weld condition data as necessary Ensure the workpiece is properly placed Ensure the error check value is set correctly. Page Page Page Page Page Page Page Page Page 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. Page 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. 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. 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. 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. 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. 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. Use correct syntax and components in control flow structures, check structure of END statements. Limit control flow structure to 10 layers. Page Re-enter the values correctly; timemilitary, dateyy/mm/dd. Include the robot number as an argument as required. Page Page Page Page Page 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. Page Page 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 Page Page Page Page Page Page 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. 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 Page Replace the 1KA/1KF boards Replace 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. 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. Page Page Page Page Page 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. Page Ensure the robot is at the home 1 position, and re-execute. Page Enter the correct center of gravity value. Set correct values for the load moment of inertia. Page 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. Page Page Page Page Page Page Page 1-211August 9, 2005 Figure 1-5 Error E1029 Flowchart (1) 1-212 August 9, 2005 Figure 1-6 Error E1029 Flowchart (2) 1-213August 9, 2005 Figure 1-7 Error E1032 Flowchart (1) 1-214 August 9, 2005 Figure 1-8 Error E1032 Flowchart (2) 1-215August 9, 2005 Figure 1-9 Error E1034 Flowchart (1) 1-216 August 9, 2005 Figure 1-10 Error E1034 Flowchart (2) 1-217August 9, 2005 Figure 1-11 Error E1035 Flowchart (1) 1-218 August 9, 2005 Figure 1-12 Error E1035 Flowchart (2) 1-219August 9, 2005 Figure 1-13 Error E1036 Flowchart (1) 1-220 August 9, 2005 Figure 1-14 Error E1036 Flowchart (2) 1-221August 9, 2005 Figure 1-15 Error E1037 Flowchart (1) 1-222 August 9, 2005 Figure 1-16 Error E1037 Flowchart (2) 1-223August 9, 2005 Figure 1-17 Error E1038 Flowchart (1) 1-224 August 9, 2005 Figure 1-18 Error E1038 Flowchart (2) 1-225August 9, 2005 Figure 1-19 Error E1039 Flowchart (1) 1-226 August 9, 2005 Figure 1-20 Error E1039 Flowchart (2)