Kawasaki MPVDCONTV113E-3 manual

D SERIES CONTR OLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT MPVDCONTV113E-3 K a a a w s k Kaw asaki Robotics ( USA), Inc. K a a a w s k[...]

This publication contains proprietar y inf ormation of Kawasaki Robotics (USA), Inc. and is fur nished solely f or customer use only . No other uses are author iz ed or per mitted without the e xpress written per mission of Kaw asaki Robotics (USA), Inc. The contents of this manual cannot be reproduced, nor transmitted b y any means , e.g., mechani[...]

REVISION HIST OR Y D SERIES CONTROLLER TR OUBLESHOOTING AND COMPONENT REPLA CEMENT K a a a w s k n o i s i v e R r e b m u N e s a e l e R e t a De g n a h C f o n o i t p i r c s e Ds l a i t i n I 0 -3 0 / 0 2 / 1 1y p o c t n i r p f o 0 - . v e R n o d e s a b , e s a e l e r F D P l a i t i n IB C / B C 1 -4 0 / 7 2 / 4y p o c t n i r p f o 1 [...]

TROUBLESHOO TING 1-1 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 1.0 TROUBLESHOO TING ................................................................................... 1-2 1.1 Error Reco v er y ............................................................................................... 1-2 1.2 P[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-2 A ugust 9, 2005 K a a a w s k 1.0 TROUBLESHOO TING This unit provides error reco v er y flowchar ts, error code inf or mation, and error code troubleshooting flo w char ts. In addition, typical causes and remedies f or the errors are also provided. 1.1 ERROR RECO V[...]

TROUBLESHOO TING 1-3 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-1 T roub leshooting Process 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 yello w reset button on the controller panel[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-4 A ugust 9, 2005 K a a a w s k Figure 1-2 T roubleshooting Process (Contin ued) Continued from pre vious pg Error still present Remov e the 1KA board from the rac k and allow RAM memor y to deplete Reinstall 1KA board, initialize the system, zero Error clears and ro[...]

TROUBLESHOO TING 1-5 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 1.2 PRELIMINAR Y TROUBLESHOO TING Pr ior to f ollo wing error code troubleshooting procedures , ensure preliminar y troub le- shooting steps are completed. 1. Ensure proper 460 V A C three-phase pow er is av ailab le at the input and ou[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-6 A ugust 9, 2005 K a a a w s k 1.2.1.1 CONTROLLER PO WER CANNO T BE SET T O ON This failure occurs when the controller does not po wer-up when the controller main disconnect is set to ON. F ailure 1: When the controller main disconnect is set to ON, circuit breaker [...]

TROUBLESHOO TING 1-7 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ⇒ Ensure primar y power supply is within specifications . Ensure pr imar y po wer supply cable is properly connected and is not damaged. ⇒ Ensure connectors at the 1KQ/1NR board are properly installed and not damaged. ⇒ Ensure the[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-8 A ugust 9, 2005 K a a a w s k 1.2.1.2 TEA CH PEND ANT IS INOPERABLE The teach pendant is in operab le with the controller main disconnect set to ON and the control power lamp is illuminated. F ailure 1: The control power lamp is illuminated and the teach pendant is[...]

TROUBLESHOO TING 1-9 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 1KX/1NX Mother Board 1KA Main CPU Board Displa y Device T each P endant Input Key s Figure 1-3 1KA/T each P endant Communication Main causes include: 1. Interr uption in data communication betw een the teach pendant and the 1KA board. 2[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-10 A ugust 9, 2005 K a a a w s k 1.2.1.3 MO T OR PO WER CANNO T BE ENABLED This condition e xists when motor power does not engage when the MO T OR PO WER s witch is pressed. Main causes include: 1. An error condition exists . 2. K1, K2, or K3 are not engaged due to [...]

TROUBLESHOO TING 1-11 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 1.2.1.4 ROBO T DOES NOT MO VE This condition e xists when the robot does not mov e when conditions are set f or teach or repeat mode. Main causes include: 1. Exter nal hold condition e xists. 2. An error condition e xists. 3. Operation[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-12 A ugust 9, 2005 K a a a w s k 1.3 ERROR CODES This unit provides inf or mation about the error codes that are displa yed on the teach pendant or other user interf aces that provide displa y screen inf or mation. The error codes are listed in numerical order by pre[...]

TROUBLESHOO TING 1-13 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 1.3.1 ERROR DISPLA Y Error messages are displa yed on the teach pendant LCD screen and/or a PC interf aced with the controller using KRter m/KCWIN32 ter minal softw are. The teach pendant LCD screen displa ys operation errors (P errors[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-14 A ugust 9, 2005 K a a a w s k 1.3.2.1 DXXXX FA T AL ERR OR CODES ERROR CODE D0001 CPU Error . (PC=XX) The 1KA board CPU has stopped (detected by the AS softw are). This error is caused by def ective AS or ser v o software , defectiv e hardware, or noise related ma[...]

TROUBLESHOO TING 1-15 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 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 b us de vices within a specific time. This error is caused by def ective AS software , defectiv e 1KA board, or noi[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-16 A ugust 9, 2005 K a a a w s k ERROR CODE D0005 [ARM CONTROL BO ARD] CPU BUS error . (PC=XX) On the 1KB board, a bus error occurs (in the VME b us line, detected b y AS software); data processing is not completed nor mally . This error is caused by def ective AS so[...]

TROUBLESHOO TING 1-17 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D0901 AS Flash memor y sum chec k error . A check sum error occurrs in AS softw are, in flash memory on the 1KA board, when the controller is powered-up . The chec k sum data is created when the FCHK command is e x ecuted an[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-18 A ugust 9, 2005 K a a a w s k ERROR CODE D0904 Memor y is lock ed due to AC_F AIL. The memor y is accessed dur ing the controller shut do wn due to a power supply abnor- mality (ACF AIL) (A VR +5 V , +12 V , -12 V , +24 V). ⇒ Cycle the controller power OFF and O[...]

TROUBLESHOO TING 1-19 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1002 Init. error of ser vo softw are. Ser vo softw are (ar msc.mb) initialization f ailure at controller power-up . Main causes include: 1. Ser vo softw are is not installed correctly or is corrupt. 2. Incompatibility betwe[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-20 A ugust 9, 2005 K a a a w s k ERROR CODE D1004 [ARM CTRL BOARD] w atch dog error of ser vo control softw are. The watch dog circuit on the 1KA board or 1KB board has detected a softw are problem. This is caused by a def ective 1KA main CPU board or 1KB ser v o CPU[...]

TROUBLESHOO TING 1-21 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1006 AMP power unit error . General ser v o system error . This error indicates that a ser v o system error has occurred. Ref er to any other servo system errors which occurred at the same time. When a ser v o error signal [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-22 A ugust 9, 2005 K a a a w s k ERROR CODE D1007 Regenerative time o v er [XX]. This error occurs when current is sent to regenerativ e resistors for six or more consecu- tive seconds . When the robot decelerates, the motors enter the po wer generation state to abso[...]

TROUBLESHOO TING 1-23 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ! WARNING ERROR CODE D1008 P-N low v oltage [XX]. The v oltage between P-N supplied to the pow er bloc k is 60 VDC or less at ser vo on. Because motor power is not supplied, when lo w v oltage occurs, the arm will fall until the error [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-24 A ugust 9, 2005 K a a a w s k ERROR CODE D1009 P-N- high voltage [XX]. The voltage betw een P-N supplied to the pow er bloc k e xceeded 410 VDC . 1KB board Additional regenerativ e resistor (option) P-N power high voltage error MC unit (1KQ/1NQ board) Primar y pow[...]

TROUBLESHOO TING 1-25 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1010 Regenerative resistor o v er-heat [XX]. The ther mal s witch f or the po wer bloc k regenerativ e resistor unit, or the optional regen- erativ e resistor unit reached 140° C (284°F), or the heat sink thermal switch r[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-26 A ugust 9, 2005 K a a a w s k ⇒ Reteach program steps to eliminate sudden high speed direction changes (dynamic shock). ⇒ Ensure cooling fans are in proper w orking condition. ⇒ Reduce controller ambient temperature. ⇒ Replace def ective thermal s witch(es[...]

TROUBLESHOO TING 1-27 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1013 P-N capacitor is not discharged. This error occurs when motor power is OFF f or a period of time and the P-N power v oltage does not decrease to 60 VDC or less . 1KB board 1KP board P-N capacitor discharge error MC uni[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-28 A ugust 9, 2005 K a a a w s k ERROR CODE D1016 Data applicable to the robot model not in servo ser v o data file. This error occurs when the installed robot model file is not f ound in the ser vo data file . ⇒ Contact KRI customer ser vice (include operating con[...]

TROUBLESHOO TING 1-29 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1500 Encoder misread error JtXX. Immediately after control power on, steady encoder data is not ab le to be read. This error is caused by a disconnected encoder signal line or a short circuit, or a defect in the main body o[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-30 A ugust 9, 2005 K a a a w s k ERROR CODE D1501 Defectiv e gun changer connection or encoder comm. error . This error occurs when the ser vo w eld gun is connected and encoder data is not read nor mally within the specified time. Main causes include: 1. Improper co[...]

TROUBLESHOO TING 1-31 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1503 Current detector type (XX) mismatch! When the control pow er supply is tur ned 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 ser vo b[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-32 A ugust 9, 2005 K a a a w s k ERROR CODE D1504 Abn. curr . f eedback Jt XX. (Amp f ail, pwr harness discon- nect). This error occurs if the current f eedback v alue is near 0 from the time the ser vo is turned ON until the brak e is released, e v en if the command[...]

TROUBLESHOO TING 1-33 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1505 Motor har ness disconnected or ov er heat. (XX) Motor thermal circuit is open due to motor overheat or harness problem. Not all robot models utilize thermal s witches in the motors. Some robot models ma y ha ve multipl[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-34 A ugust 9, 2005 K a a a w s k ERROR CODE D1506 P ower module error JtXX. An error signal from the IPM module in the power b loc k is detected by the 1KB board. 1KB board IPM error signal P ower b lock Gate Arra y Servo CPU Interface CPU PWM signal Controller HIC I[...]

TROUBLESHOO TING 1-35 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1507 A C primar y power OFF . This error occurs when there is an instantaneous decrease in the primar y power to the A VR f or control po wer supply (130–145 V A C or less for 20–30 msec). Mother Board 1KP board 1KB boa[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-36 A ugust 9, 2005 K a a a w s k ERROR CODE D1508 24VDC power source is too lo w . 24 VDC to the power sequence board has dropped to +21.6 VDC or less. Mother Board 1KP board 1KB board 1KX board EPLD 24 VDC monitor A VR for control power Main disconnect Primar y powe[...]

TROUBLESHOO TING 1-37 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1509 Primar y power source is too high. V oltage le vel of the A VR f or the control power supply is too high (267-277 V AC or more f or 1-2 sec.). Mother Board 1KP board 1KX board EPLD AV R output cut A VR for control powe[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-38 A ugust 9, 2005 K a a a w s k ERROR CODE D1510 Pr imar y pow er source is too low . V oltage le vel of the A VR primar y pow er supply is too low (150-158 V A C or less for 1-2 sec.). Mother Board 1KP board 1KB board 1KX board EPLD A VR for control power Main disc[...]

TROUBLESHOO TING 1-39 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1511 +12VDC or -12VDC is abnor mal. +/-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. Def ective A VR. 2. Def ective 1KA, 1KB , or[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-40 A ugust 9, 2005 K a a a w s k ERROR CODE D1512 Brak e line error f or JtXX. This error occurs when the 1KB board detects an error signal sent from the brak e re- lease control MOSFET on the 1KQ/1NR board. T ransformer Circuit breaker MOSFET V oltage monitoring 1KP[...]

TROUBLESHOO TING 1-41 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k necessar y . ⇒ Check and repair br ak e power line and connections as necessary . ⇒ Check and repair connections betw een 1KB and 1KQ/1NR, 1KB and 1KX/1NX, and 1NR and 1NX as necessar y . ⇒ Ensure the 1KB board is properly seated[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-42 A ugust 9, 2005 K a a a w s k ERROR CODE D1514 I/O 24V fuse is open. Fuse F2 on the 1KP board is open. Main causes include: 1. Solenoid valv e or diode polarity rev ersed. 2. Current load on the 24 VDC I/O circuit exceeds rating. 3. Shor t-circuit or ground f ault[...]

TROUBLESHOO TING 1-43 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1517 Blown fuse on saf ety circuit emergency line . Fuse F1 on the 1KP board is open. Main causes include: 1. Incorrect wir ing in the emergency line (wiring har ness, emergency stop , safety f ence, e xter nal trigger , te[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-44 A ugust 9, 2005 K a a a w s k ERROR CODE D1519 Mismatch of the safety circuit LS condition. In a double saf ety circuit system, conditions set for contacts in the limit s witch (LS) circuit do not match. Main causes include: 1. Defectiv e harness connection or har[...]

TROUBLESHOO TING 1-45 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1522 Mismatch in cond. of safety circuit enab ling device . In a double saf ety circuit system, conditions set for contacts at the TRIGGER s witch circuit do not match. If the trigger switch is not pressed firmly , only one[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-46 A ugust 9, 2005 K a a a w s k ERROR CODE D1525 Incorrect operation of MC (K1). Main causes include: 1. Defectiv e controller harness. 2. Defectiv e magnetic contactor K1. 3. Defectiv e MC unit (1KQ/1NQ board). 4. Defectiv e 1KP board. ⇒ Replace controller har ne[...]

TROUBLESHOO TING 1-47 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D1528 Controller temperature is out of range . T emperature inside the controller e xceeds specification. Main causes include: 1. Def ective cooling f an(s). F or D7X controller , defectiv e heat e xchange f an on the left s[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-48 A ugust 9, 2005 K a a a w s k ERROR CODE D1531 Heat sink on power b lock o v erheated. Main causes include: 1. T emperature inside the controller abov e specification because of air inlet or outlet bloc kage. 2. Defectiv e cooling f an. 3. Defectiv e power b lock.[...]

TROUBLESHOO TING 1-49 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D2002 No response from the ar m ID board. Main causes include. 1. Def ective 1KB board. 2. Def ective 1KP board. 3. Def ective 1GV arm ID board. 4. Def ective harness. 5. Noise related malfunction. ⇒ Replace 1KB board. ⇒[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-50 A ugust 9, 2005 K a a a w s k ERROR CODE D2006 Communication board to e xplosion-proof teach pendant watch-dog error . This error occurs when the CPU on the communication board (1GS board) f or the e xplo- sion-proof teach pendant is suspended. Main causes include[...]

TROUBLESHOO TING 1-51 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D2011 P arameter do wnload error between user I/F & arm ctr l boards. 1KA and 1KB boards parameter e xchange cannot be downloaded. ⇒ Replace the 1KA board. ⇒ Replace the 1KB board. ___________________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-52 A ugust 9, 2005 K a a a w s k ERROR CODE D2016 No response from the ar m 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 . ________________________________[...]

TROUBLESHOO TING 1-53 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D2020 [ARM CTRL BOARD] servo control softw are no response. 1KB board software stopped. Main causes include: 1. Ser vo softw are is not installed correctly or is corrupt. 2. Def ective 1KB board. ⇒ Reinstall correct 1KB bo[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-54 A ugust 9, 2005 K a a a w s k ERROR CODE D2024 [ARM CTRL BOARD] robot type setting f ailed. System software is not compatib le with the robot model set in the AS software . ⇒ Ensure the correct model setting is used . ⇒ Ensure the correct software v ersion is [...]

TROUBLESHOO TING 1-55 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D2028 (SSCNET) initialization error . (code XX). The Mitsubishi single axis amplifier f ailed to initialize at controller po wer-up . A 2 b yte code f ollows the error message . The higher byte indicates axis number and the [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-56 A ugust 9, 2005 K a a a w s k ERROR CODE D2031 Codes set in software and on add’l pwr b lock mismatch. (Jt-A) Software and hardw are settings, f or the axis assigned to channel 7 (sev enth axis), do not match pow er bloc k settings. ⇒ Ensure correct power b lo[...]

TROUBLESHOO TING 1-57 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE D2035 Program e x ecution error . Progr am failed to star t when cycle star t command was issued. ⇒ Reset the error , and restar t the program . ⇒ If the error recurs, contact KRI Customer Service . _____________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-58 A ugust 9, 2005 K a a a w s k 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 maxim um I/O data leng[...]

TROUBLESHOO TING 1-59 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 1.3.2.2 EXXXX NON-FA T AL ERROR CODES ERROR CODE E0001 Unknown error . Unregistered error occurred. ⇒ Contact KRI customer ser vice (include operating conditions/settings and operation log at the time the error occurred) . __________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-60 A ugust 9, 2005 K a a a w s k ERROR CODE E0103 Location data is not defined. Main causes include: 1. The location variab le f or the BASE, T OOL or POINT command is not specified. Example: “T OOL a” is specified and “a” is not defined. 2. DEST or #DEST fun[...]

TROUBLESHOO TING 1-61 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E0108 Divided by z ero . Occurs when the system encounters a mathematical e v aluation that inv olves division b y “0”. T ypically associated with the FRAME function and circular inter polation. ⇒ Check data source f o[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-62 A ugust 9, 2005 K a a a w s k ERROR CODE E0113 No expressions to e valuate . The type of data in an argument is incompatible with the oper ation being perf or med. ⇒ Correct the program to e valuate compatible e xpressions. ______________________________________[...]

TROUBLESHOO TING 1-63 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E0118 T oo many subroutine calls . Occurs when more than 20 subroutines are nested with EXTCALL or CALL instructions. ⇒ Do not e xceed 20 nested subroutines. ________________________________________________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-64 A ugust 9, 2005 K a a a w s k ERROR CODE E1001 ADC input range error . This error occurs when an A/D conv e r ter input v oltage is incorrect. The correct analog input voltage r anges are: 1. 0– +10 V 2. ±5 V 3. ±10 V ⇒ Ensure the correct analog input voltag[...]

TROUBLESHOO TING 1-65 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1004 Interbus board is not ready . At 1JF board star t-up, the board did not achie ve the ready state within the required time . ⇒ Cycle controller pow er OFF and ON . ⇒ Ensure the 1JF board is correctly installed. ⇒ [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-66 A ugust 9, 2005 K a a a w s k ERROR CODE E1008 No .2 po wer sequence board is not installed. The first address of the No .2 1KP power sequence board cannot be read at controller pow er-up . Main causes include: 1 . The 1KP power sequence board is not installed in [...]

TROUBLESHOO TING 1-67 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1010 P ower sequence board detects error . An error signal, not classified through the error summar y , is generated b y the 1KP board and is sent to the 1KB board. This error occurs when the error signal sent from the 1KP [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-68 A ugust 9, 2005 K a a a w s k 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 [...]

TROUBLESHOO TING 1-69 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1021 Ar m ID board error . (code XXX). e d o Cn o i t p i r c s e D H A 4 t p u r r o c s i r o l a m r o n t o n s i a t a d d r a o b D I m r A H F 4 y r o m e m d r a o b D I m r a o t r o r r e g n i t i r W 1 H 1 C r o[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-70 A ugust 9, 2005 K a a a w s k ERROR CODE E1023 Communication error in robot network. Main causes include: 1. Communication between robots is not normal dur ing cooperative motion operation. 2. P ower to one of the controllers connected to the network is not set ON[...]

TROUBLESHOO TING 1-71 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1025 EXT AXIS connecting error . (code XX) Occurs when the gun axis connection is not nor mally completed. e d o Cn o i t p i r c s e D 0 . e r a w t f o s o v r e s m o r f e s n o p s e r o N * * F E . N O s i O S G R e s[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-72 A ugust 9, 2005 K a a a w s k ERROR CODE E1027 Saf ety circuit was cut OFF . The safety gate br anch of the saf ety circuit is open due to a missing saf ety plug or def ective circuit. ⇒ Reinser t the safety plug. ⇒ Repair open circuit. _______________________[...]

TROUBLESHOO TING 1-73 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 6. Malfunction of the motor . 7. Ser vo spot w eld gun: –Clamping pressure and/or clamping time is e xcessive . –Distance between weld points is short; the motor does not hav e time to cool suffi- ciently between welds . –Clampin[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-74 A ugust 9, 2005 K a a a w s k ERROR CODE E1029 Encoder rotation data is abnor mal. (Jt XX) Occurs when there is a diff erence (+2 rotations or more) between the rotation data in the ser ial encoder data and the rotation data calculated using the incremental tech- [...]

TROUBLESHOO TING 1-75 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1030 Encoder data abnormal. (Jt XX) When control pow er is s witched ON, the current encoder v alue is compared to the stored encoder v alue when the power is turned OFF . If the diff erence is more than the v alue set in A[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-76 A ugust 9, 2005 K a a a w s k ERROR CODE E1031 Miscount of encoder data (Jt XX). The ser v o gun or tool changer har ness is def ective. ⇒ Inspect the ser vo gun and tool changer harnesses; replace if necessar y . ________________________________________________[...]

TROUBLESHOO TING 1-77 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1034 Encoder initialize error (Jt XX). The encoder is not ab le 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 o[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-78 A ugust 9, 2005 K a a a w s k 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. Po we r circuit Battery Encoder Encoder 1FG/1HG board Robot Controller 1KB boa[...]

TROUBLESHOO TING 1-79 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1036 Encoder communication error . (Jt XX) Cyclic redundancy check (CRC) f ault or framing error is detected in communication with the encoder . Po we r circuit Battery Encoder Encoder 1FG/1HG board Robot Controller 1KB boa[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-80 A ugust 9, 2005 K a a a w s k ERROR CODE E1037 Encoder data conv ersion error . (Jt XX). This error is caused by abnormal encoder absolute position data. Po we r circuit Battery Encoder Encoder 1FG/1HG board Robot Controller 1KB board Encoder I/F Servo CPU Encoder[...]

TROUBLESHOO TING 1-81 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1038 Encoder ABS-trac k error . (Jt XX) The absolute data and the incremental data in the encoder are diff erent. ABSALM=1 is output from the encoder when this error occurs. Po we r circuit Battery Encoder Encoder 1FG/1HG b[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-82 A ugust 9, 2005 K a a a w s k ERROR CODE E1039 Encoder INC-pulse error . (Jt XX) Occurs when the encoder A and B incremental pulses are abnor mal. The encoder INALM bit is sent with the serial data=1. Po we r circuit Battery Encoder Encoder 1FG/1HG board Robot Con[...]

TROUBLESHOO TING 1-83 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1041 Limit s witch (JT XX) is ON. This error occurs when the robot mov es bey ond the set working range (restricted space) and activates the axis restriction limit s witch. The mechanical stopper and the axis restriction li[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-84 A ugust 9, 2005 K a a a w s k ERROR CODE E1042 Limit s witch signal line is disconnected. This error occurs when the axis restriction limit switch is activ ated and the robot did not mov e be yond the set w orking range (restr icted space). The mechanical stopper [...]

TROUBLESHOO TING 1-85 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1045 Gun-clamp Mismatch. (Spot weld specifications type B) Spot weld is not selected in A UX 0605-1 when a ser vo spot w eld gun is used. ⇒ Ensure spot weld is selected in A UX 0605-1. ____________________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-86 A ugust 9, 2005 K a a a w s k ERROR CODE E1050 Encoder and brak e power off signal not dedicated. A gun change is e x ecuted on a ser v o spot weld gun without setting [Encoder and brak e power (7)] dedicated signal in A UX 0602. ⇒ F rom A UX 0602 Dedicated outp[...]

TROUBLESHOO TING 1-87 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1054 Cannot e x ecute motion instr uction. Main causes include: 1. A motion instruction is ex ecuted for the sla ve robot during cooperativ e motion. 2. A motion instr uction is e x ecuted in soft absorber mode (from SAST A[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-88 A ugust 9, 2005 K a a a w s k ERROR CODE E1058 SLA VE robot already e xists. This error occurs when SLA VE instructions are ex ecuted for both connected robots dur ing cooperativ e motion in repeat mode. ⇒ Do not e x ecute SLA VE instructions f or both robots at[...]

TROUBLESHOO TING 1-89 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1063 JT2 and JT3 interf ere dur ing motion to end pose . Mov ement from the current position to the end pose would cause JT2 and JT3 to mov e bey ond their limits . ⇒ Modify the position of the end pose of the program. __[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-90 A ugust 9, 2005 K a a a w s k ERROR CODE E1067 Illegal patter n type. Main causes include: 1. Program step does not comply with AS Language syntax. 2. P attern type for w ork specified using block step instructions or the P ALLET function is not between 1 and 5. ?[...]

TROUBLESHOO TING 1-91 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1071 XMO VE signal is already input. An XMO VE instr uction mode “/ERR” is specified and the signal condition to monitor is already attained when monitor ing star ts. ⇒ Delete the “/ERR” mode from the XMO VE instr[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-92 A ugust 9, 2005 K a a a w s k ERROR CODE E1076 Cannot use negative time v alue. Displa yed when a negativ e number is entered as par t of a DELA Y or TIMER command. ⇒ Correct the time setting to a positive n umber . ______________________________________________[...]

TROUBLESHOO TING 1-93 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1081 Cannot use negativ e value . Displa yed when a negativ e number is used in conjunction with the PULSE or A CCURA CY commands/instructions. ⇒ Use only positive n umbers in the acceptable r ange for the PULSE and A CCU[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-94 A ugust 9, 2005 K a a a w s k ERROR CODE E1086 Star t point for Jt XX be yond motion r ange. Robot pose at motion star t is beyond the r ange set in A UX 0507. Example: DO HOME is ex ecuted at a point that is out of motion range set in A UX 0507. ⇒ Correct pose [...]

TROUBLESHOO TING 1-95 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1090 Exter nal modulation data is not input. (Option) Exter nal modulation data is not received. ⇒ Check f or abnor mality in the e xter nal modulation data line and repair as necessar y . ________________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-96 A ugust 9, 2005 K a a a w s k ERROR CODE E1095 Cannot ex ecute motion instr uction in PC program. A PC program cannot contain instructions that initiate robot motion. ⇒ Correct the PC program b y removing motion instructions. ____________________________________[...]

TROUBLESHOO TING 1-97 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1100 Cannot e x ecute in sealing specification. Occurs when a CLOSE(I), OPEN(I), or RELAX(I) command is e x ecuted in a program and clamp specifications in A UX 0605-1 are set for sealing. ⇒ Correct progr am instr uctions[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-98 A ugust 9, 2005 K a a a w s k ERROR CODE E1106 Cannot ex ecute in this robot. This error occurs when a request is ex ecuted on a robot ar m that does not suppor t the function. ⇒ Contact KRI customer ser vice to hav e the function installed or delete the request[...]

TROUBLESHOO TING 1-99 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1113 W ork sensing signal is not detected. (sensing function) This error occurs when the X-linear step is e x ecuted and the workpiece is not detected bef ore the robot ax es reach coincidence of the taught point. The sensi[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-100 A ugust 9, 2005 K a a a w s k ERROR CODE E1117 Process time ov er . Lack of system processing time ⇒ Contact KRI customer ser vice (include operating conditions/settings and operation log at the time the error occurred) . _______________________________________[...]

TROUBLESHOO TING 1-101 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1119 Commanded value f or Jt XX bey ond motion range . Spot Welding and Material Handling The commanded position f or the joint identified e xceeds the software limits . Condition is monitored in both the check and repeat [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-102 A ugust 9, 2005 K a a a w s k ERROR CODE E1122 Une xpected motor pow er OFF . Occurs when software turns motor power ON (K1 or K2 contactors ON) b ut there is no signal f eedback (MCON) indicating motor po wer is ON. Main causes include: 1. Defect in the 1KP po w[...]

TROUBLESHOO TING 1-103 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1124 De viation error of Jt XX. Spot Welding and Material Handling The diff erence between the current v alue from the encoder and the command value in the AS software e xceeds the regulated v alue (v ar ies b y robot mode[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-104 A ugust 9, 2005 K a a a w s k 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 e xceeds the v alue range. Main causes include: 1. A sudden change in robot motion. 2. Defecti[...]

TROUBLESHOO TING 1-105 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1128 Uncoincidence error betw destination and current Jt XX pos. This error occurs dur ing program e xecution, if all joints do not reach total coincidence within the commanded accuracy and time. Main causes include. Mecha[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-106 A ugust 9, 2005 K a a a w s k ERROR CODE E1130 Jt XX collision was detected. Motor current command value e xceeds the threshold value set in A UX 0510. ⇒ Remov e obstacles in the robot motion path area. ⇒ Ensure tool settings are correct. ⇒ If an obstacle w[...]

TROUBLESHOO TING 1-107 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1134 Abnor mal work transf er pitch. The signal f or resetting the conv e y or value is receiv ed before the con v e yor reached the position specified by the w or k transf er pitch. ⇒ Ensure the work transf er pitch is [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-108 A ugust 9, 2005 K a a a w s k ERROR CODE E1138 A ux. ter minal is not connected. Exter nal monitor ing de vice is not connected. ⇒ Ensure the e xter nal monitoring device is properly connected . __________________________________________________________________[...]

TROUBLESHOO TING 1-109 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1143 Conv ey or axis number is not set. Conv ey or axis number is not set at e x ecution of conv e y or synchronous motion. ⇒ Set the conv e y or axis number using the ZCV AXIS instr uction . ____________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-110 A ugust 9, 2005 K a a a w s k 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 memor y c[...]

TROUBLESHOO TING 1-111 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1154 Option SIO por t is not installed. Main causes include: 1. Optional communication por t (1GS board) is not installed to the 1KA board. 2. Optional communication por t (1GS board) is not recognized by the 1KA board. ?[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-112 A ugust 9, 2005 K a a a w s k ERROR CODE E1157 Ar m ID I/F board error . (code XXX) e d o Cn o i t p i r c s e D H 1 C r o r r e m u s k c e h c n o i t a c i n u m m o C 1 H 5 C r o r r e l o c o t o r p n o i t a c i n u m m o C 1 H 6 C r o r r e t u o - e m i [...]

TROUBLESHOO TING 1-113 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E1162 Buff er ov erflow occurred g ra vity comp . value channel XX. Gra vity compensation v alue ov erflow due to mismatch of load weight and the set v alue. ⇒ Contact KRI customer ser vice (include operating conditions/s[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-114 A ugust 9, 2005 K a a a w s k ERROR CODE E1167 Unable to do wnload e xt. axis parameter . (Jt-B) Download f ailed due to channel 8 parameter is being do wnloaded by another process . ⇒ Re-ex ecute parameter download. ⇒ If this error recurs, contact KRI custom[...]

TROUBLESHOO TING 1-115 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 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 , ABOR T or PCABOR T durin[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-116 A ugust 9, 2005 K a a a w s k ERROR CODE E4004 Communication retr y error . Communication retry error dur ing Host Communication I. Main causes include: 1. No response after sending te xt. 2. After text is sent, NAK (resend request) e xceeded the allowed number o[...]

TROUBLESHOO TING 1-117 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E4009 Communication time out error . During Host Communication I or TCP/IP interface , data is not receiv ed within the al- low ed time after ex ecuting the RECEIVE instr uction. ⇒ Ensure communication protocol used f or [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-118 A ugust 9, 2005 K a a a w s k ERROR CODE E4014 TELNET) RECV error . CODE=XX. During TCP/IP communication, data is not receiv ed due to a RECV (receiv e) error . ⇒ Check the comm unication line to the target end node and repair as necessar y . ⇒ Check f or pro[...]

TROUBLESHOO TING 1-119 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E4018 TELNET) System error . CODE=XX. P arameter settings entered using the NETCONF command does not comply with AS Language syntax. The code (CODE=xx) indicates a detailed SUB error code f or the TCP/IP package . ⇒ Ref e[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-120 A ugust 9, 2005 K a a a w s k ERROR CODE E4021 TCP/IP) Communication Error . CODE=XX Dst.IP=xx.xx.xx.xx. A communication error occurred during ex ecution of the UDP_SENDT O/ UDP_RECVFROM/TCP_SEND/TCP_RECV instruction. Ma y be a problem with the Ether net line or [...]

TROUBLESHOO TING 1-121 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E4025 TCP/IP) Connection abor ted. Communication is disconnected during ex ecution of the UDP_SENDT O/ UDP_RECVFROM/TCP_CONNECT/TCP_SEND/TCP_RECV/TCP_A CCEPT instr uc- tion. Ma y be a problem with the Ethernet line or at th[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-122 A ugust 9, 2005 K a a a w s k ERROR CODE E4029 FTP) Data send error . (code=XX). F ailure to transmit the teach data via Memor y → LAN (Manual SA VE). Ma y be a comm u- nication cable connection prob lem. ⇒ Ensure the communication cable connections are corre[...]

TROUBLESHOO TING 1-123 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E4034 FTP) f ailed to receive HOST OS inf or mation. (code=XX) Error occurred during receiving OS information from the ser ver . ⇒ Ensure the communication cab le is proper ly connected, and re-e x ecute. ⇒ Reboot the F[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-124 A ugust 9, 2005 K a a a w s k ERROR CODE E4052 [FDD/PC_CARD] F ailed to set verify function. Please set again. F ailure to set condition for v erify function for the 1KF board. ⇒ Re-set condition f or verify function in A UX 0208 . _____________________________[...]

TROUBLESHOO TING 1-125 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E4056 TCP) This por t is not in LISTEN (SOCK). Main causes include: 1. F ailure to open the sock et when ex ecuting TCP_A CCEPT . 2. F ailure to close the sock et when e x ecuting TCP_END_LISTEN. ⇒ Ensure correct por t nu[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-126 A ugust 9, 2005 K a a a w s k ERROR CODE E4501 ANYBUS) OUT/FB .CTRL release timeout. XX Access to the input signal reading area is not released due to defectiv e hardw are. ⇒ Check LED indicator on the interf ace card, and reset the error . ⇒ If the error mes[...]

TROUBLESHOO TING 1-127 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E4521 ABMA-PDP) Status OFFLINE. XX An error occurred in the ABMA-PDP module, and the status of An yBus PROFIBUS-DP master changed to OFFLINE. ⇒ Use the sub-sub-code XX as a troubleshooting aid, clear the cause of the erro[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-128 A ugust 9, 2005 K a a a w s k ERROR CODE E4525 ABMA-PDP) Timeout of sending message. XX ABMA-PDP module ov erload, sending message cannot be processed within the allowed time. ⇒ Check the fieldb us cab le and connections, repair/replace as necessar y . ⇒ Use [...]

TROUBLESHOO TING 1-129 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E4529 PROFIB US) Statistic counter-error response detected. XX Incorrect slav e diagnosis command parameter is entered. ⇒ Use the sub-code XX as a troubleshooting aid, clear the cause of the error and reset the error . ?[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-130 A ugust 9, 2005 K a a a w s k ERROR CODE E5003 Illegal e xtend (retract) output signal. Occurs when the output signals f or the e xtend and retract operation of a spot welding application are not proper ly set. ⇒ Check the setting in A UX 0605. ________________[...]

TROUBLESHOO TING 1-131 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E5007 Ser vo w eld gun not connected or wrong gun connected. (Ser v o spot weld gun only) Main causes include: 1. The robot e x ecutes a step when a gun is not attached to the tool changer . 2. The gun number in the tool ch[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-132 A ugust 9, 2005 K a a a w s k ERROR CODE E5010 Ser vo weld gun mechanical par ameter is not set. (Ser vo spot w eld gun only) A new gun is connected and the mechanical par ameters are not defined in A UX 1021. ⇒ Define the parameters in A UX 1021. _____________[...]

TROUBLESHOO TING 1-133 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E5015 Gun status data disagrees with clamp condition. (Ser v o 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[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-134 A ugust 9, 2005 K a a a w s k ERROR CODE E5018 W eld completion signal has not been detected. Occurs when a weld complete signal is not receiv ed in the allow ed time per iod. Main causes include: 1. Defectiv e weld gun, weld controller/timer , cabl e, etc. 2. De[...]

TROUBLESHOO TING 1-135 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E5021 Extend pos. monitor error . Occurs when the input signal for the e xtend operation of a 2-stroke retr actable gun is not received. Main causes include: 1. Def ective weld gun, weld controller/timer , cabl e, etc. 2. D[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-136 A ugust 9, 2005 K a a a w s k ERROR CODE E5024 Pressur ization comp . signal has not been detected. Pressur ization completion signal is not receiv ed from the weld controller/timer . Main causes include: 1. Defectiv e weld controller/timer . 2. Defectiv e ser v [...]

TROUBLESHOO TING 1-137 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E5027 Robot stopped dur ing weld. (Spot weld specifications type C) (Ser v o spot weld gun only) This error occurs when the robot is placed in a HOLD or an E-ST OP condition after the clamp output signal is sent, and bef or[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-138 A ugust 9, 2005 K a a a w s k ERROR CODE E5030 Copper plate wear e xceeds limit. step=XX. (Ser vo spot w eld gun only) The copper backing plate w ear exceeds the copper plate w ear limit (A UX 1029). The error is detected when the gun e x ecutes a weld. ⇒ Repla[...]

TROUBLESHOO TING 1-139 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E5033 Cannot weld because of abnor mal thic kness. (Ser v o spot weld gun only) The thickness of the workpiece is out of tolerance . Main causes include: 1. Defectiv e workpiece. 2. Incorrect positioning of the workpiece. 3[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-140 A ugust 9, 2005 K a a a w s k ERROR CODE E6002 Signal condition already input. The signal condition is already met when an XDMO VE or XD(2)ST ART mo v e is e x- ecuted and the signal monitoring star ts. ⇒ Check input signal timing f or the door open detection s[...]

TROUBLESHOO TING 1-141 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6007 Wr ist can’t be straightened an y 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. This does not nor mally occur in j[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-142 A ugust 9, 2005 K a a a w s k ERROR CODE E6012 Relative distance betw een guns is too near . The gun tips of two networked robots is less than the minim um specified distance for the application. ⇒ If this error occurs in teach mode, drive the ax es so the dist[...]

TROUBLESHOO TING 1-143 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6502 Arc f ailure. The signal (current detection: WCR) that indicates the robot is e x ecuting the weld w as not returned from the weld controller/timer within 1 second, or less, after welding star ted. Main causes include[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-144 A ugust 9, 2005 K a a a w s k ERROR CODE E6505 Arc weld insulation def ect. This error occurs when robot mov ement causes insulation f ailure. ⇒ Ensure the welder , torch, and robot insulation are in good working condition. _____________________________________[...]

TROUBLESHOO TING 1-145 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6510 Undefined sensing direction. (T ouch sensing) Occurs when the step proceeding the W ORK_DETECT instruction is not an air_cut point. ⇒ Inser t an air_cut point in the program bef ore the W ORK_DETECT instruction . ?[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-146 A ugust 9, 2005 K a a a w s k ERROR CODE E6512 Undefined mother or daughter work. (T ouch sensing) Main causes include: 1. A pre vious work instr uction is not completed bef ore another work instr uction is e x- ecuted. 2. Program e x ecution is star ted at a ste[...]

TROUBLESHOO TING 1-147 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6514 W ork specification incorrect. (T ouch sensing) Occurs when a pre vious work instr uction is not completed bef ore another work instr uc- tion is e x ecuted. Example: 1. A C JOINT SPEED9 A CCU4 TIMER0 MO THER_RESET 2.[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-148 A ugust 9, 2005 K a a a w s k ERROR CODE E6516 Wire check f ailure. (T ouch sensing) Main causes include: 1. The position of a taught point is recorded too f ar from the workpiece, and the wire tip did not touch the work within the allowed time . 2. The weld wire[...]

TROUBLESHOO TING 1-149 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6519 W eld condition data out of range . Ensure data is within range as sho wn below . Current: 0–999 Amp V oltage: 0–99.9 V olt Speed: 0–999 cm/min Time: 0–9.9 second W ea ving width: 0–40.0 mm W ea ving frequen[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-150 A ugust 9, 2005 K a a a w s k ERROR CODE E6522 Laser sensor cannot detect welding joint. Main causes include: 1. The laser sensor unable to find a g roov e. 2. The laser sensor detects a groov e that does not match the specified groov e number data. 3. The laser [...]

TROUBLESHOO TING 1-151 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6526 No response from laser sensor controller . Main causes include: 1. Disconnected or def ective laser sensor harness. 2. Incorrect laser sensor settings or def ective laser sensor . ⇒ Check laser sensor , laser sensor[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-152 A ugust 9, 2005 K a a a w s k ERROR CODE E6529 Finish point not f ound by laser sensor . Main causes include: 1. The laser sensor unable to find a g roov e. 2. Auto tr acking function is enab led with no data present, and finish point detection f ailed. ⇒ Re-te[...]

TROUBLESHOO TING 1-153 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6533 No R TPM board. Main causes include: 1. The software f or RTPM option is installed, b ut the hardware (1FH board) is not in- stalled properly . 2. Hardware f or R TPM (1FH board) is installed, but the softw are f or R[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-154 A ugust 9, 2005 K a a a w s k ERROR CODE E6536 R TPM current deviation error . Occurs when actual current exceeds commanded current (f eedback current) f or a time per iod e xceeding the current de viation error time-out v alue. Main causes include: 1. Weld start[...]

TROUBLESHOO TING 1-155 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6538 Bey ond R TPM trac king ability . Occurs when the current trac king v alue e xceeds the threshold v alue and the number of times value set f or RTPM tr ac king ability errors. Example: If the threshold is set at 9 mm,[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-156 A ugust 9, 2005 K a a a w s k ERROR CODE E6540 Bey ond A VC trac king ability . Occurs when the current trac king v alue e xceeds the threshold v alue and the number of times value set f or RTPM tr ac king ability errors. Main causes include: 1. Weld start-point [...]

TROUBLESHOO TING 1-157 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE E6543 T oo many taught points f or A VC . Occurs when the number of taught points between the w eld star t point and the weld end point e xceeds 127 points. ⇒ Reteach program points , not to e xceed 127 R TPM points . ___[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-158 A ugust 9, 2005 K a a a w s k ERROR CODE E8200 Not in cooperative mode . Cooperativ e motion instr uction is taught bef ore MASTER/SLA VE instruction or after ALONE instruction. ⇒ Use cooperativ e motion instr uctions between MASTER/SLA VE instr uction and ALON[...]

TROUBLESHOO TING 1-159 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k 1.3.2.3 PXXXX OPERA TION 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. ______________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-160 A ugust 9, 2005 K a a a w s k ERROR CODE P0106 Illegal pr iority . Prior ity le vel designation is out of the allo wab le range (1–127) . Example: LOCK 128 ⇒ Ensure the correct pr iority lev el n umber is entered (1–127). Example: LOCK 2 ___________________[...]

TROUBLESHOO TING 1-161 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P0111 Cannot use this command/instr uction in current mode . The command/instr uction entered could not be e x ecuted in the selected mode . Example: “EDIT” is entered in the program edit mode (used in monitor mode). Ex[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-162 A ugust 9, 2005 K a a a w s k ERROR CODE P0117 Inv alid v ariable (or program) name . Displa yed when illegal v ariable or prog ram name is entered from the editor or monitor modes. Example: “JM ##a” too many precision point symbols. Example: “CALL #a” is[...]

TROUBLESHOO TING 1-163 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P0121 Expected to be a binar y operator . A non-binar y operator has been entered where a command e xpected a binar y operator . ⇒ Enter a binar y operator . _______________________________________________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-164 A ugust 9, 2005 K a a a w s k ERROR CODE P0126 Illegal s witch name. Displa yed when a system s witch is incorrectly identified. Example: “SWITCH light” there is no system s witch named “light”. ⇒ Use valid s witch names. _______________________________[...]

TROUBLESHOO TING 1-165 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P0131 No . of dimension in arra y e xceeds 3. Attempted to create an arra y v ariable with more than 3 dimensions . Example: “point[3,5,7,9]=1” retur ns an error . ⇒ Use 3 or less dimensions (elements) in an arra y . [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-166 A ugust 9, 2005 K a a a w s k ERROR CODE P0135 Local variab le expected. A global variab le is used when defining a temporar y argument f or a subroutine. Example: “SUB(a)” returns an error . ⇒ Use a local v ar iab le when defining a temporary argument for [...]

TROUBLESHOO TING 1-167 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P0139 Illegal control structure. Main causes include: 1. In a control str ucture CASE is the last step , or V ALUE, END , or ANY are missing after CASE. 2. Destination step f or str ucture instruction is missing. ⇒ Use co[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-168 A ugust 9, 2005 K a a a w s k ERROR CODE P0144 Step:XX Preceding IF missing. Displa yed when control flo w str ucture does not contain the correct structure for IF…THEN… ELSE…END commands. ⇒ Use correct syntax and components in control flow structures. __[...]

TROUBLESHOO TING 1-169 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P0149 V ariable (or prog ram) already exists . The name of a progr am, loaded from flopp y disk or PC card using the LOAD command, already e xists in the system memor y . This error is not used in the spot welding applica- [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-170 A ugust 9, 2005 K a a a w s k ERROR CODE P0153 Illegal clock v alue. Time or date is entered in the wrong f or mat. ⇒ Re-enter the v alues correctly; time—militar y , date—yy/mm/dd. _____________________________________________________________________ ERROR[...]

TROUBLESHOO TING 1-171 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P0158 Missing “BY”. The argument is missing the necessar y “BY”. Example: “POINT y = SHIFT (x 5,5,5) ⇒ Ensure command/instr uction complies with AS Language syntax and f ormat. Example: “POINT y = SHIFT (x BY [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-172 A ugust 9, 2005 K a a a w s k ERROR CODE P0162 Cannot modify position data in this instr uction. Dur ing modifying an AS Language progr am from the teach screen, pose data is modi- fied at a step with a non-positional command/instr uction. Example: T r ying to mo[...]

TROUBLESHOO TING 1-173 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P1003 Cannot e xecute a prog ram because of EXT .HOLD input. An attempt to cycle star t a program is made while e xternal hold signal is ON. ⇒ Release the e xter nal hold and re-e x ecute cycle star t. ⇒ V e rify dedica[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-174 A ugust 9, 2005 K a a a w s k ERROR CODE P1009 Program is already running. Main causes include: 1. An attempt is made to edit or e x ecute a program that is running. 2. SYSINIT command is e xecuted while a program is running. ⇒ Stop the robot control program pr[...]

TROUBLESHOO TING 1-175 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P1014 Cannot e xecute because prog ram already in use . An attempt to e x ecute the same program using the EXECUTE and PCEXECUTE is made. ⇒ Allow the prog ram to complete e x ecuting and re-e x ecute. ____________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-176 A ugust 9, 2005 K a a a w s k 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 progr am to complete e xecution and re-enter the instructions. ⇒ Stop the PC program an[...]

TROUBLESHOO TING 1-177 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P1024 Statement cannot be e xecuted. Occurs when the AS Language instr uction entered is not acceptab le f or the mode of operation. Example: DO HOME is ex ecuted with TEACH LOCK ON. ⇒ Use instr uctions and commands that [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-178 A ugust 9, 2005 K a a a w s k ERROR CODE P1029 Program name not specified. Displa yed when no prog ram is on the stac k and the EDIT command is entered without specifying a program name . ⇒ Specify the name of the progr am to edited. ___________________________[...]

TROUBLESHOO TING 1-179 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P1034 This program is not editab le. The auto load measurement program cannot be edited. ⇒ Use a program name that does not include the auto load measurement progr am name. ________________________________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-180 A ugust 9, 2005 K a a a w s k ERROR CODE P1039 T each pendant is not connected . The “T” command is e x ecuted without the teach pendant connected. ⇒ Install teach pendant and re-e x ecute the “T” command. _______________________________________________[...]

TROUBLESHOO TING 1-181 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2000 T ur n OFF motor pow er . An attempt is made to e x ecute an operation or command which is not permitted with motor pow er ON. Example: ZZERO command. ⇒ T ur n motor po wer OFF and re-e x ecute operation or command.[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-182 A ugust 9, 2005 K a a a w s k 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. _____________________________________________________________________ ER[...]

TROUBLESHOO TING 1-183 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2011 Inv alid disk format. Incorrect disk f or mat. ⇒ Ensure the disk f ormat is: 2HD , 1.44 MB or 1.25 MB . _____________________________________________________________________ ERROR CODE P2012 Disk is write protected.[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-184 A ugust 9, 2005 K a a a w s k ERROR CODE P2016 Cannot open the file. The file cannot be opened with the SA VE or LO AD commands. ⇒ Ensure the flopp y disk is proper ly inser ted into the flopp y disk dr iv e . ⇒ Ensure an existing file name is used. ⇒ Defec[...]

TROUBLESHOO TING 1-185 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2022 Cannot use DOUBLE O X. When DOUBLE type signals are used, if either output signal in the pair is set ON, the other is set to OFF . An instr uction (BITS, PULSE, DL YSIG, etc.) to change the state of either output sign[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-186 A ugust 9, 2005 K a a a w s k ERROR CODE P2026 Inv alid coordinate v alue Z. This error occurs when the work space output signal lower Z v alue is greater than the upper value in A UX 0403. ⇒ Ensure upper and lower v alues are set correctly in A UX 0403 . _____[...]

TROUBLESHOO TING 1-187 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2032 Incorrect number input as WHERE parameter . Occurs if a numeric value entered with the WHERE command is not in the acceptabl e range. Example: WHERE 100. ⇒ Ensure that data is within acceptable r ange. Example: WHER[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-188 A ugust 9, 2005 K a a a w s k ERROR CODE P2039 Cannot star t cycle from FN instr uction. This error occurs when an FN instruction is the first step at cycle star t . ⇒ Do not e x ecute cycle star t at a step containing an FN instr uction. ______________________[...]

TROUBLESHOO TING 1-189 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2045 Cannot format this card. An attempt is made to f or mat a non-SRAM PC card. ⇒ Use a PC to f ormat a non-SRAM card . _____________________________________________________________________ ERROR CODE P2046 Card initial[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-190 A ugust 9, 2005 K a a a w s k ERROR CODE P2051 Illegal sequence numbers f or file I/O data. Dur ing data transf er 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 .[...]

TROUBLESHOO TING 1-191 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2055 [LSEQ] Program is already running. During ex ecution of the basic operation par t of the sequence function of the KLogic progr am, the program is e x ecuted again b y the LSQEXECUTE command/instruction. ⇒ Place the [...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-192 A ugust 9, 2005 K a a a w s k ERROR CODE P2059 [Ser ialFlash] data write error . The specified file cannot be written to the 1KA board. Main causes include: 1. The file is corr upt. 2. The ser ial flash memor y on the 1KA board is set to write-protect. ⇒ Ensure[...]

TROUBLESHOO TING 1-193 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2064 [FDD] No space av ailab le. Flopp y disk has less than 12 KB of free space and the data cannot be sav ed. ⇒ Inser t a floppy disk with sufficient free space and re-e x ecute . ⇒ Delete unnecessar y data from the f[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-194 A ugust 9, 2005 K a a a w s k ERROR CODE P2069 [FDD/PC_CARD] Device already in use . Attempting to perf or m se ver al processes at the same time to/from the flopp y disk/PC card. The next task is commanded while the pre viously commanded task is in progress. ⇒[...]

TROUBLESHOO TING 1-195 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P2074 Flopp y disk is broken. This error occurs when ten or more def ective sectors are detected on a flopp y disk. ⇒ Use a new or kno wn good flopp y disk. ________________________________________________________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-196 A ugust 9, 2005 K a a a w s k ERROR CODE P4502 DEVNET) Already in that mode. An attempt is made to change the operation mode setting, using the DEVNET com- mand, to the mode that is currently set. ⇒ Ensure the correct parameter is set and re-e xecute the DEVNET[...]

TROUBLESHOO TING 1-197 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P5002 Spot sequence is r unning. Step change, prog ram change, or prog ram e x ecution attempted while the spot weld sequence is e x ecuting (after Retract/Extend input signal and weld complete signal are receiv ed). Exampl[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-198 A ugust 9, 2005 K a a a w s k ERROR CODE P6500 Cannot generate working line direction. This error occurs when weld star t and end points are the same, and motion direction cannot be deter mined. ⇒ Ensure the star t and end points are not the same. _____________[...]

TROUBLESHOO TING 1-199 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE P7000 Cannot program reset, because not at home position 1. The robot is not at the registered home 1 position, and the progr am reset signal is ignored. ⇒ Ensure the robot is at the home 1 position, and re-e x ecute. ___[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-200 A ugust 9, 2005 K a a a w s k 1.3.2.4 WXXXX MECHANICAL/CONTROL WARNING ERROR CODES ERROR CODE W1000 Cannot mov e along straight line JTXX in this configuration. When operating manually in teach mode and in base or tool mode , axis (JTXX) speed e xceeds capability[...]

TROUBLESHOO TING 1-201 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE W1005 Illegal center of gra vity , default par ameter is set. Load mass value is set to a v alue other than zero , but the center of gr avity is set to all zeroes . ⇒ Enter the correct center of gra vity v alue. _________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-202 A ugust 9, 2005 K a a a w s k ERROR CODE W1010 RAM batter y low v oltage. Main causes include: 1. Backup battery voltage belo w minimum v alue (3.3 VDC or less). 2. Defectiv e batter y harness. 3. Defectiv e 1KA board. ⇒ Back up system and prog ram data. Check [...]

TROUBLESHOO TING 1-203 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE W1013 Encoder batter y low v oltage [Ser v o (XX)]. V oltage of the encoder back up batter y on the 1FG/1HG board decreased to 3.3 v olts or less, or the encoder batter y alarm signal (BAL_AL) is disconnected. This error is[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-204 A ugust 9, 2005 K a a a w s k ERROR CODE W1015 P ossibility of failure . The monitored value of I 2 (current squared) e xceeds the nor mal v alue f or the monitored program and indicates e xcessiv e wear in the cyclo reduction unit or a ser v o motor/brake proble[...]

TROUBLESHOO TING 1-205 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE W1018 Network parameter is changed. T ur n OFF & ON the control power . When network setting data is changed, the controller power m ust be cycled OFF and ON. ⇒ Cycle controller pow er OFF and ON . ___________________[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-206 A ugust 9, 2005 K a a a w s k ERROR CODE W4501 FIELD-BUS) Master por t OFFLINE. Master por t is offline due to communication line ter mination. ⇒ Check the sla v e and communication line and repair as necessary . When repairs are completed wait f or on-line sta[...]

TROUBLESHOO TING 1-207 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE W5004 W eld controller XX response error . During communication with the weld controller , data received from the weld controller does not conf orm to the specified protocol. ⇒ Ensure the welder connection is estab lished[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-208 A ugust 9, 2005 K a a a w s k ERROR CODE W5007 (Spot welding) Weld f ault XX. This error occurs when a weld complete signal is not receiv ed by the robot controller from the remote weld controller (R WC), or there is an electrical malfunction with the RW C. Code [...]

TROUBLESHOO TING 1-209 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k ERROR CODE W5010 (Spot welding) Main cab le exchange alarm XX. The present v alue of the counter f or the specified weld gun e xceeds the set value f or initiating an alar m to replace the main cab le (XX indicates gun number). ⇒ Re[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-210 A ugust 9, 2005 K a a a w s k 1.4 TROUBLESHOO TING FLO WCHARTS The f ollowing flo wchar ts are arranged by error code number . Refer also to the corre- sponding error code inf or mation in section 1.3.2.2 during troubleshooting procedures.[...]

TROUBLESHOO TING 1-211 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-5 Error E1029 Flowchar t (1) Error E1029 END No 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[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-212 A ugust 9, 2005 K a a a w s k Figure 1-6 Error E1029 Flowchar t (2) Service call A Replace 1FG/1HG board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Does problem still exist? END No Ye s Check inside machine harness and separation [...]

TROUBLESHOO TING 1-213 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-7 Error E1032 Flowchar t (1) Error E1032 No 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 boa[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-214 A ugust 9, 2005 K a a a w s k Figure 1-8 Error E1032 Flowchar t (2) Service call A Replace 1FG/1HG board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Does problem still exist? END No Ye s Check inside machine harness and separation [...]

TROUBLESHOO TING 1-215 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-9 Error E1034 Flowchar t (1) Error E1034 Does the encoder revolve over 300 RPM? (For conveyor encoder) Check connections at the encoder connector Does problem still exist? END Reduce conveyor encoder revolution speed under 30[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-216 A ugust 9, 2005 K a a a w s k Figure 1-10 Error E1034 Flowchar t (2) Replace 1FG/1HG board Service call A Check machine harness and separation harness Replace 1KB board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Does problem still[...]

TROUBLESHOO TING 1-217 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-11 Error E1035 Flowchar t (1) Error E1035 Can y ou reset the error? Check connections at the encoder connector Does problem still exist? END Retr y robot program execution or manual operation carefull y Check connections on t[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-218 A ugust 9, 2005 K a a a w s k Figure 1-12 Error E1035 Flowchar t (2) Service call A Replace 1KB board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Replace 1FG/1HG board Does problem still exist? END No Ye s Check machine harness and[...]

TROUBLESHOO TING 1-219 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-13 Error E1036 Flowchar t (1) Error E1036 Can y ou reset the error? Check connections at the encoder connector Does problem still exist? END Retr y robot program execution or manual operation carefull y Check connections on t[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-220 A ugust 9, 2005 K a a a w s k Figure 1-14 Error E1036 Flowchar t (2) Service call A Replace 1KB board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Replace 1FG/1HG board Does problem still exist? END No Ye s Check machine harness and[...]

TROUBLESHOO TING 1-221 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-15 Error E1037 Flowchar t (1) Error E1037 Can y ou reset the error? Retr y robot program execution or manual operation carefull y END Ye s Does the error reoccur? No No Ye s Check connections at the encoder connector Check co[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-222 A ugust 9, 2005 K a a a w s k Figure 1-16 Error E1037 Flowchar t (2) Service call A Replace 1FG/1HG board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Does problem still exist? END No Ye s Check inside machine harness and separation[...]

TROUBLESHOO TING 1-223 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-17 Error E1038 Flowchar t (1) Error E1038 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 b[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-224 A ugust 9, 2005 K a a a w s k Figure 1-18 Error E1038 Flowchar t (2) Service call A Replace 1FG/1HG board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Check inside machine harness and separation harness[...]

TROUBLESHOO TING 1-225 A ugust 9, 2005 D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLACEMENT K a a a w s k Figure 1-19 Error E1039 Flowchar t (1) Error E1039 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[...]

TROUBLESHOO TING D SERIES CONTROLLER TR OUBLESHOO TING AND COMPONENT REPLACEMENT 1-226 A ugust 9, 2005 K a a a w s k Figure 1-20 Error E1039 Flowchar t (2) Service call A Replace 1FG/1HG board Does problem still exist? END No Ye s Does problem still exist? END No Ye s Does problem still exist? END No Ye s Check inside machine harness and separation[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-1 K a a a w s k 2.0 COMPONENT REPLACEMENT This chapter describes replacement procedure for parts inside the controller: printed boards, power blocks, hardware including A VR, etc., and, units. 2.1 General Safe ty Preca utions on R eplacem ent·····················[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-2 K a a a w s k 2.1 GENERAL SAFETY PRECAUTIONS ON REPLACEMENT This section describes the precautions to be ta ken when replacing parts due to trouble, etc. This information is presented h ere for use as general precautions. In addition to these, adhere the safety measures required fo[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-3 K a a a w s k 7. Use only Kawa saki approved parts duri ng replacement. 8. When replacing printed boards, do not fail to turn OFF control pow er . T o replace power block, MC unit, or A VR, wait at least seven minutes after control power OFF before removing connectors. Then confirm[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-4 K a a a w s k 18. Printed boards and power blocks are designed dif ferently for each robot model. Be sure to replace the correct ty pe. 19. When air or water is supplied, shut OFF the supply source and pur ge any remaining pressure from the lines before starting any replacement pro[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-5 K a a a w s k 2.2.1 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 d ata to storage me dia such as PCCARD, FDD, etc. For more details about data saving p[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-6 K a a a w s k 2.2.2 1KB BOARD (ARM CONTROL BOARD) 1. T urn OFF the con trol 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. Confirm that settings for SW1 to SW8 and[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-7 K a a a w s k 2 .2.3 1KP BOARD (POWER SEQUENCE BOARD) 1. T urn OFF the con trol 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 c[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-8 K a a a w s k 6. Confir m the voltage at each check pin on th e 1KA and 1KP as shown below . 1KA board No. Color S tandard Allowable rang e If the voltage is out of allowabl e range, TP2 Y ellow − 12.0 V − 1 1.95 V ∼ − 12.05 V Adjust the volu me on the A VR. TP3 Y ellow +12[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-9 K a a a w s k 2 .2.5 1NR BOARD (BRAKE CONTROL BOARD) 1. T urn OFF the con trol 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 connect or, remove the co[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-10 K a a a w s k 2.3 REPLA CEMENT PROCEDUR E FOR POWER BLOCK UN IT This section describes the replacement procedure for the power block unit mounte d in the controller . Four types of power block are available as described below . 1. 1KC: Power block for large robot (six axes) 2. 1KD[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-1 1 K a a a w s k 1. Remove all connectors connected to the power block unit. 2. Loosen the four screws fixing the power bl ock unit to the controller so that the power block unit can be removed from the controller . (The se screws are not re m ove d from the power block unit.) 3. T [...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-12 K a a a w s k 2.3.3 1KD POWE R BLOCK UN IT (FOR D7X CONTRO LLER) 1. Remove the controller c over . 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 p[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-13 K a a a w s k Fixing screws (two in lower corners) Fixing screws (two in upper corners) X302 X31 1[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-14 K a a a w s k 2.3. 4 1KL POW ER BLO CK UNI T 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[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-15 K a a a w s k 2.4 REPLACEMEN T PROCEDURE FOR MC UNIT P ARTS (FOR D3X CONTRO LLER) This section describes the replacement procedur e for the MC unit (power supply unit) and the 1KQ board (power circuit board) which flanks the MC unit. 2.4. 1 MC UNI T 1. T o facilitate the replacem [...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-16 K a a a w s k 2.4.2 1KQ BOARD (POWER CIRCUIT BOARD) 1. Remove the MC unit. For details, refe r to 2.4.1 MC Unit. 2. Remove the four screws fixing the 1KQ board assy to the MC unit (1 to 4 in figure below), the one screw fixing the fan unit of the MC unit (5 in figure below), and t[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-17 K a a a w s k 4. Loosen the five nuts fixing the 1KQ to the plate (1 to 5 in figure below), and re move the 1KQ. 5. Attach the new 1KQ to the pl ate 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. R[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-18 K a a a w s k 2 .5 REPLA CEMENT PROCEDURE FOR 1NQ BOARD (FOR D7X CONTRO LLER) This section describes the replacement proce dure for the 1N Q board (power circuit board) 1. T urn OFF the con trol power . 2. Remove the power block unit. (For the pr ocedure, see 2.3.3 1KD Power Block[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-19 K a a a w s k 2 .6 REPLACEMENT PROCED URE FOR F AN (FOR D3X CONTROLLER) Fans are installed for the card rack, the power blo ck unit, and the MC unit. This section describes the repl acement procedure for these fans. 2.6.1 F AN FOR CARD RAC K 1. T urn OFF the con trol power . 2. Re[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-20 K a a a w s k 2 .6.2 F ANS ON THE BACK OF CONTROLLER This section describes the replacement procedur es for the two fans mounted on the controller back. The upper fan cannot be seen from outside. 2.6.2.1 UPPER F AN ON BACK OF CONT ROLLER 1. T urn OFF the con trol power . 2. Remove[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-21 K a a a w s k 2 .6.2. 2 LOWER F AN ON BACK O F CO NTR O L L ER 1. T urn OFF the con trol power . 2. Remove the six screws fixing the plate on th e controller back. 3. Pull out the plate, remove the connector connected to the controller , and remove the plate. 4. Remove the power l[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-22 K a a a w s k 2 .6.3 MC UNIT F AN 1. T urn OFF the con trol power . 2. Remove the two screws at the bottom of the MC unit (1 and 2 in figure below) and pull ou t the plate. Remove the connecter connected to the 1KQ board and remove the fan unit. 3. Remove the four screws fixing th[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-23 K a a a w s k 2 .7 REPLACEMENT PROCED URE FOR F AN (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 F AN FOR CARD RAC K 1. T urn OF[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-24 K a a a w s k 2.7.2 F AN FOR PO WER BLO C K UNIT 1. T urn OFF the con trol power . 2. Remove the four screws fixing the cover on th e controller back, and then remove the cover . 3. Remove the four screws fixing the fan. 4. Remove the power line and the earth wire conn ected to th[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-25 K a a a w s k 2 .7.3 HEA T EXCHANGE F AN (FOR D71/74/77 CONTROLLER) Heat exchange fan is inst alled on the left side of t he controller cover . 1. T urn OFF the con trol power . 2. Remove the controller c over . 3. Remove the power harness from the bands which fix the harness. 4. [...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-26 K a a a w s k 2.8 REPLA CEMENT PROCEDUR E FOR BA TTERIES This section describes the replacement proce dure for the battery provided to backup data. 2.8.1 BA TTER Y ON 1KA BOARD As backup power supply for SRAM and R TC (Real T i me Clock), the 1KA board is equipped with a lithium b[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-27 K a a a w s k 2.8.2 BA TTER Y ON 1FG/1HG BO AR D 1. Record the encoder value for all axes before replacing a ba ttery . 2. Before replacing the battery , confir m that the new battery has +3.6V or more voltage . 3. T urn OFF the con trol power . 4. For the 1HG board, pull out the [...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-28 K a a a w s k 2.9 REPLA CEMENT PROCEDUR E FOR FUSES This section describes the replac em ent procedure for the fuses. 2.9.1 FUSES ON 1K P BOARD T wo types of fuses- Fuse1 and Fuse2 - are mounted on the 1KP board. 1. T urn OFF the con trol power . 2. Push the fuse on the front of t[...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-29 K a a a w s k 2.9.2 FUSES ON 1NQ BOARD (FOR D7X C ONTROLLER) 1. T urn OFF the con trol power . 2. Remove the controller c over . 3. T urn the fuse 90 degr ees to the left. Then pull it out and remove th e fuse from the board. 4. Push in the new fuse, and turn it 90 degrees to the [...]

D SERIES CONTROLLER TROUBLESHOO TING AND COMPONENT REPLA CEMENT 2-30 K a a a w s k 2.10 REPLACEMEN T PROCEDURE FOR FIL TER W ash filt ers periodically to keep them clean. For replacement, follow the replacement procedure described below . Filters are located on the side and back of the controller . T ake the same procedure to replace these filters.[...]