Instruction/ maintenance manual of the product MPVDCONTV113E-3 Kawasaki
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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.
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 - .
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 ......
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.
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 t.
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 st.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
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 .
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).
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.
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.
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.
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 .
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.
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].
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].
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.
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 .
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 .
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.
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.
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.
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.
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.
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.
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).
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 .
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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 .
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.
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 .
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 .
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.
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.
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.
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 .
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 .
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.
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.
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 .
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.
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 .
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.
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 .
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.
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 .
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).
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.
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 .
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 .
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.
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.
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.
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).
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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 .
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 .
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.
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.
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 .
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.
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.
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.
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.
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 .
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.
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 .
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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 .
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.
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).
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 .
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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).
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 .
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.
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 .
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”.
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 .
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 .
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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 .
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 .
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.
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.
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 .
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.
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.
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.
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.
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 .
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.
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.
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).
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.
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.
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.
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 .
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.
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.
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 .
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.
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 .
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.
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.
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).
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.
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 en.
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 pro.
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 encode.
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 pro.
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 .
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 m.
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 c.
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 proble.
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 c.
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 proble.
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 .
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 pr.
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 enco.
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 pr.
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 .
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 pr.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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 .
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.
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 .
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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 .
An important point after buying a device Kawasaki MPVDCONTV113E-3 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki MPVDCONTV113E-3 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki MPVDCONTV113E-3 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki MPVDCONTV113E-3 you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki MPVDCONTV113E-3 will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki MPVDCONTV113E-3, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki MPVDCONTV113E-3.
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki MPVDCONTV113E-3. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki MPVDCONTV113E-3 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
