Page 2 - For additional information contact:
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. andis furnished solely for customer use only. No other uses are authorized or permittedwithout the express written permission of Kawasaki Robotics (USA), Inc. The contentsof this manual cannot be reproduced, nor trans...
Page 3 - REVISION HISTORY; Ka a a
REVISION HISTORY D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka 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 D e g n a h C f o n o i t p i r c s e D s l a i t i n I 0 - 3 0 / 0 2 / 1 1 y 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 I ...
Page 4 - TROUBLESHOOTING
TROUBLESHOOTING 1-1 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k 1.0 TROUBLESHOOTING ................................................................................... 1-2 1.1 Error Recovery ..................................................................
Page 6 - Figure 1-1 Troubleshooting Process
TROUBLESHOOTING 1-3 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k Figure 1-1 Troubleshooting 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 ...
Page 8 - PRELIMINARY TROUBLESHOOTING; D Series
TROUBLESHOOTING 1-5 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k 1.2 PRELIMINARY TROUBLESHOOTING Prior to following error code troubleshooting procedures, ensure preliminary trouble-shooting steps are completed. 1. Ensure proper 460 VAC three-phase power ...
Page 9 - Defective F1 circuit breaker.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-6 August 9, 2005 Ka a a w s k 1.2.1.1 CONTROLLER POWER CANNOT BE SET TO ON This failure occurs when the controller does not power-up when the controller maindisconnect is set to ON. Failure 1: When the controller main di...
Page 10 - Ensure the 1KP board fuses F1 and F2 are not open.
TROUBLESHOOTING 1-7 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ⇒ Ensure primary power supply is within specifications. Ensure primary power supplycable is properly connected and is not damaged. ⇒ Ensure connectors at the 1KQ/1NR board are properly insta...
Page 11 - +12 VDC is not supplied to the teach pendant.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-8 August 9, 2005 Ka a a w s k 1.2.1.2 TEACH PENDANT IS INOPERABLE The teach pendant is in operable with the controller main disconnect set to ON and thecontrol power lamp is illuminated. Failure 1: The control power lamp...
Page 12 - KA Main CPU Board; Figure 1-3 1KA/Teach Pendant Communication
TROUBLESHOOTING 1-9 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k 1KX/1NX Mother Board 1KA Main CPU Board Display Device Teach Pendant InputKeys Figure 1-3 1KA/Teach Pendant Communication Main causes include:1. Interruption in data communication between th...
Page 14 - External hold condition exists.; WARNING
TROUBLESHOOTING 1-11 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k 1.2.1.4 ROBOT DOES NOT MOVE This condition exists when the robot does not move when conditions are set for teach orrepeat mode. Main causes include:1. External hold condition exists. 2. An ...
Page 15 - Table 1-1 provides an explanation of the error code prefixes.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-12 August 9, 2005 Ka a a w s k 1.3 ERROR CODES This unit provides information about the error codes that are displayed on the teachpendant or other user interfaces that provide display screen information. The errorcodes ...
Page 16 - Figure 1-4 Teach Pendant Error Screen Display
TROUBLESHOOTING 1-13 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k 1.3.1 ERROR DISPLAY Error messages are displayed on the teach pendant LCD screen and/or a PC interfacedwith the controller using KRterm/KCWIN32 terminal software. The teach pendant LCD scre...
Page 17 - Replace the 1KA board.; Replace the 1KA board.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-14 August 9, 2005 Ka a a w s k 1.3.2.1 DXXXX FATAL ERROR CODES ERROR CODE D0001 CPU Error. (PC=XX) The 1KA board CPU has stopped (detected by the AS software). This error is causedby defective AS or servo software, defec...
Page 18 - Ensure the correct 1KB board software is loaded into the 1KA board.
TROUBLESHOOTING 1-15 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka 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 busdevices within a specific time. This error is caused by defective A...
Page 20 - AS Flash memory sum check error.
TROUBLESHOOTING 1-17 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D0901 AS Flash memory sum check error. A check sum error occurrs in AS software, in flash memory on the 1KA board, when thecontroller is powered-up. The check sum data is created...
Page 21 - Cycle the controller power OFF and ON.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-18 August 9, 2005 Ka a a w s k ERROR CODE D0904 Memory is locked due to AC_FAIL. The memory is accessed during the controller shut down due to a power supply abnor-mality (ACFAIL) (AVR +5 V, +12 V, -12 V, +24 V). ⇒ Cycle...
Page 23 - Replace the AS or servo software.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-20 August 9, 2005 Ka a a w s k ERROR CODE D1004 [ARM CTRL BOARD] watch dog error of servo controlsoftware. The watch dog circuit on the 1KA board or 1KB board has detected a software problem.This is caused by a defective...
Page 24 - AMP power unit error.
TROUBLESHOOTING 1-21 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1006 AMP power unit error. General servo system error. This error indicates that a servo system error has occurred.Refer to any other servo system errors which occurred at the s...
Page 26 - Ensure the motor power circuit connector is properly attached.
TROUBLESHOOTING 1-23 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ! WARNING ERROR CODE D1008 P-N low voltage [XX]. The voltage between P-N supplied to the power block is 60 VDC or less at servo on. Because motor power is not supplied, when low voltageoccu...
Page 27 - Replace the regenerative unit.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-24 August 9, 2005 Ka a a w s k ERROR CODE D1009 P-N- high voltage [XX]. The voltage between P-N supplied to the power block exceeded 410 VDC. 1KB board Additional regenerativeresistor (option) P-N power highvoltage error...
Page 28 - regenerative resistor unit.
TROUBLESHOOTING 1-25 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1010 Regenerative resistor over-heat [XX]. The thermal switch for the power block regenerative resistor unit, or the optional regen-erative resistor unit reached 140° C (284°F),...
Page 30 - Replace the power block.
TROUBLESHOOTING 1-27 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1013 P-N capacitor is not discharged. This error occurs when motor power is OFF for a period of time and the P-N powervoltage does not decrease to 60 VDC or less. 1KB board 1KP ...
Page 31 - Error of download of servo data.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-28 August 9, 2005 Ka a a w s k ERROR CODE D1016 Data applicable to the robot model not in servo servo datafile. This error occurs when the installed robot model file is not found in the servo data file. ⇒ Contact KRI cus...
Page 32 - Encoder misread error JtXX.
TROUBLESHOOTING 1-29 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1500 Encoder misread error JtXX. Immediately after control power on, steady encoder data is not able to be read. Thiserror is caused by a disconnected encoder signal line or a s...
Page 33 - Defective gun changer connection or encoder comm. error.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-30 August 9, 2005 Ka a a w s k ERROR CODE D1501 Defective gun changer connection or encoder comm. error. This error occurs when the servo weld gun is connected and encoder data is not readnormally within the specified ti...
Page 34 - Ensure the correct AS software is loaded.
TROUBLESHOOTING 1-31 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1503 Current detector type (XX) mismatch! When the control power supply is turned ON, the ID code data of the 1GM (1KV) boardand the AS software installed on the 1KB board do no...
Page 35 - Check the power line wiring and repair or replace as necessary.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-32 August 9, 2005 Ka a a w s k ERROR CODE D1504 Abn. curr. feedback Jt XX. (Amp fail, pwr harness discon-nect). This error occurs if the current feedback value is near 0 from the time the servo is turnedON until the brak...
Page 36 - Confirm continuity of thermal line.
TROUBLESHOOTING 1-33 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1505 Motor harness disconnected or over heat. (XX) Motor thermal circuit is open due to motor overheat or harness problem. Not all robotmodels utilize thermal switches in the mo...
Page 38 - AC primary power OFF.
TROUBLESHOOTING 1-35 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1507 AC primary power OFF. This error occurs when there is an instantaneous decrease in the primary power to theAVR for control power supply (130–145 VAC or less for 20–30 msec)...
Page 39 - 4VDC power source is too low.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-36 August 9, 2005 Ka a a w s k ERROR CODE D1508 24VDC power source is too low. 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 AVR for c...
Page 40 - Primary power source is too high.
TROUBLESHOOTING 1-37 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1509 Primary power source is too high. Voltage level of the AVR for the control power supply is too high (267-277 VAC or morefor 1-2 sec.). Mother Board 1KP board 1KX board EPLD...
Page 41 - Primary power source is too low.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-38 August 9, 2005 Ka a a w s k ERROR CODE D1510 Primary power source is too low. Voltage level of the AVR primary power supply is too low (150-158 VAC or less for 1-2sec.). Mother Board 1KP board 1KB board 1KX board EPLD...
Page 42 - Adjust the AVR output voltage.
TROUBLESHOOTING 1-39 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1511 +12VDC or -12VDC is abnormal. +/-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. De...
Page 43 - Brake line error for JtXX.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-40 August 9, 2005 Ka a a w s k ERROR CODE D1512 Brake line error for JtXX. This error occurs when the 1KB board detects an error signal sent from the brake re-lease control MOSFET on the 1KQ/1NR board. Transformer Circui...
Page 46 - Blown fuse on safety circuit emergency line.
TROUBLESHOOTING 1-43 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1517 Blown fuse on safety circuit emergency line. Fuse F1 on the 1KP board is open. Main causes include:1. Incorrect wiring in the emergency line (wiring harness, emergency stop...
Page 48 - NOTE
TROUBLESHOOTING 1-45 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D1522 Mismatch in cond. of safety circuit enabling device. In a double safety circuit system, conditions set for contacts at the TRIGGER switchcircuit do not match. If the trigge...
Page 52 - No response from the arm ID board.
TROUBLESHOOTING 1-49 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D2002 No response from the arm ID board. Main causes include.1. Defective 1KB board.2. Defective 1KP board.3. Defective 1GV arm ID board.4. Defective harness.5. Noise related mal...
Page 53 - Replace defective 1GS board.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-50 August 9, 2005 Ka a a w s k ERROR CODE D2006 Communication board to explosion-proof teach pendantwatch-dog error. This error occurs when the CPU on the communication board (1GS board) for the explo-sion-proof teach pe...
Page 58 - Lower byte 3: connect amplifier or motor.
TROUBLESHOOTING 1-55 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE D2028 (SSCNET) initialization error. (code XX). The Mitsubishi single axis amplifier failed to initialize at controller power-up. A 2 bytecode follows the error message. The high...
Page 67 - ADC input range error.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-64 August 9, 2005 Ka a a w s k ERROR CODE E1001 ADC input range error. This error occurs when an A/D converter input voltage is incorrect.The correct analog input voltage ranges are: 1. 0– +10 V2. ±5 V3. ±10 V ⇒ Ensure t...
Page 69 - No.2 power sequence board is not installed.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-66 August 9, 2005 Ka a a w s k ERROR CODE E1008 No.2 power sequence board is not installed. The first address of the No.2 1KP power sequence board cannot be read at controllerpower-up. Main causes include:1. The 1KP powe...
Page 72 - Replace serial flash memory on the 1GV board.
TROUBLESHOOTING 1-69 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1021 Arm ID board error. (code XXX). e d o C n 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 ...
Page 75 - Safety circuit was cut OFF.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-72 August 9, 2005 Ka a a w s k ERROR CODE E1027 Safety circuit was cut OFF. The safety gate branch of the safety circuit is open due to a missing safety plug ordefective circuit. ⇒ Reinsert the safety plug. ⇒ Repair open...
Page 76 - ciently between welds.; Servo Spot Weld Gun
TROUBLESHOOTING 1-73 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k 6. Malfunction of the motor.7. Servo spot weld gun: –Clamping pressure and/or clamping time is excessive.–Distance between weld points is short; the motor does not have time to cool suffi- ...
Page 77 - Check for noise and shield integrity.; For additional information on error code E1029, see section 1.4.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-74 August 9, 2005 Ka a a w s k ERROR CODE E1029 Encoder rotation data is abnormal. (Jt XX) Occurs when there is a difference (+2 rotations or more) between the rotation data inthe serial encoder data and the rotation dat...
Page 78 - Ensure the value set in AUX 0504 is correct.
TROUBLESHOOTING 1-75 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1030 Encoder data abnormal. (Jt XX) When control power is switched ON, the current encoder value is compared to thestored encoder value when the power is turned OFF. If the diff...
Page 79 - The servo gun or tool changer harness is defective.; For additional information on error code E1032, see section 1.4.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-76 August 9, 2005 Ka a a w s k ERROR CODE E1031 Miscount of encoder data (Jt XX). The servo gun or tool changer harness is defective. ⇒ Inspect the servo gun and tool changer harnesses; replace if necessary. ____________...
Page 80 - Ensure the 1KB board is properly seated into the card rack.; For additional information on error code E1034, see section 1.4.
TROUBLESHOOTING 1-77 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1034 Encoder initialize error (Jt XX). The encoder is not able to read the absolute position at control power on. The scanningof absolute data begins immediately after a shift f...
Page 81 - For additional information on error code E1035, see section 1.4.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-78 August 9, 2005 Ka 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 signalfrom the 1KB board. Powercircuit Battery Encoder Encode...
Page 82 - Check for noise malfunction and shield integrity.; For additional information on error code E1036, see section 1.4.
TROUBLESHOOTING 1-79 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1036 Encoder communication error. (Jt XX) Cyclic redundancy check (CRC) fault or framing error is detected in communication withthe encoder. Powercircuit Battery Encoder Encoder...
Page 83 - This error is caused by abnormal encoder absolute position data.; For additional information on error code E1037, see section 1.4.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-80 August 9, 2005 Ka a a w s k ERROR CODE E1037 Encoder data conversion error. (Jt XX). This error is caused by abnormal encoder absolute position data. Powercircuit Battery Encoder Encoder 1FG/1HG board Robot Controller...
Page 84 - For additional information on error code E1038, see section 1.4.
TROUBLESHOOTING 1-81 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1038 Encoder ABS-track error. (Jt XX) The absolute data and the incremental data in the encoder are different. ABSALM=1 isoutput from the encoder when this error occurs. Powerci...
Page 85 - For additional information on error code E1039, see section 1.4.; Replace the encoder or encoder harness.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-82 August 9, 2005 Ka a a w s k ERROR CODE E1039 Encoder INC-pulse error. (Jt XX) Occurs when the encoder A and B incremental pulses are abnormal. The encoderINALM bit is sent with the serial data=1. Powercircuit Battery ...
Page 86 - Set the software limits in AUX 0507 to an appropriate value.
TROUBLESHOOTING 1-83 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1041 Limit switch (JT XX) is ON. This error occurs when the robot moves beyond the set working range (restricted space)and activates the axis restriction limit switch. The mecha...
Page 88 - Ensure spot weld is selected in AUX 0605-1.
TROUBLESHOOTING 1-85 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1045 Gun-clamp Mismatch.(Spot weld specifications type B) Spot weld is not selected in AUX 0605-1 when a servo spot weld gun is used. ⇒ Ensure spot weld is selected in AUX 0605-...
Page 90 - Cannot execute motion instruction.
TROUBLESHOOTING 1-87 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1054 Cannot execute motion instruction. Main causes include:1. A motion instruction is executed for the slave robot during cooperative motion.2. A motion instruction is executed...
Page 93 - Illegal pattern type.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-90 August 9, 2005 Ka a a w s k ERROR CODE E1067 Illegal pattern type. Main causes include:1. Program step does not comply with AS Language syntax.2. Pattern type for work specified using block step instructions or the PA...
Page 97 - Star t point for Jt XX beyond motion range.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-94 August 9, 2005 Ka a a w s k ERROR CODE E1086 Star t point for Jt XX beyond motion range. Robot pose at motion star t is beyond the range set in AUX 0507.Example:DO HOME is executed at a point that is out of motion ran...
Page 103 - Lack of system processing time; Spot Welding and Material Handling; Change the posture of the robot.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-100 August 9, 2005 Ka a a w s k ERROR CODE E1117 Process time over. Lack of system processing time ⇒ Contact KRI customer service (include operating conditions/settings and operationlog at the time the error occurred). _...
Page 106 - Deviation error of Jt XX.; Main causes include or the following abnormalities:; Inspect the workpiece replace it if necessary.
TROUBLESHOOTING 1-103 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1124 Deviation error of Jt XX. Spot Welding and Material Handling The difference between the current value from the encoder and the command value inthe AS software exceeds the ...
Page 108 - Repair mechanical or electrical failures as necessary.
TROUBLESHOOTING 1-105 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1128 Uncoincidence error betw destination and current Jt XXpos. This error occurs during program execution, if all joints do not reach total coincidencewithin the commanded acc...
Page 113 - Cannot open setting data, so cannot set to shipment state.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-110 August 9, 2005 Ka 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 filein the setting file (...
Page 114 - Option SIO por t is not installed.
TROUBLESHOOTING 1-111 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1154 Option SIO por t is not installed. Main causes include:1. Optional communication port (1GS board) is not installed to the 1KA board.2. Optional communication port (1GS boa...
Page 115 - Refer to the message displayed after the error message.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-112 August 9, 2005 Ka a a w s k ERROR CODE E1157 Arm ID I/F board error. (code XXX) e d o C n 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 ...
Page 116 - Buffer overflow occurred gravity comp. value channel XX.
TROUBLESHOOTING 1-113 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E1162 Buffer overflow occurred gravity comp. value channel XX. Gravity compensation value overflow due to mismatch of load weight and the set value. ⇒ Contact KRI customer servi...
Page 117 - If this error recurs, contact KRI customer service.; If error cannot be reset, cycle controller power OFF and ON.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-114 August 9, 2005 Ka a a w s k ERROR CODE E1167 Unable to download ext. axis parameter. (Jt-B) Download failed due to channel 8 parameter is being downloaded by another process. ⇒ Re-execute parameter download. ⇒ If thi...
Page 118 - Data communication error.
TROUBLESHOOTING 1-115 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka 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 stopp...
Page 122 - Ensure during multiple socket openings do not exceed limits.
TROUBLESHOOTING 1-119 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E4018 TELNET) System error. CODE=XX. Parameter settings entered using the NETCONF command does not comply with ASLanguage syntax. The code (CODE=xx) indicates a detailed SUB err...
Page 123 - Check for problems at the target end node and repair as necessary.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-120 August 9, 2005 Ka a a w s k ERROR CODE E4021 TCP/IP) Communication Error. CODE=XXDst.IP=xx.xx.xx.xx. A communication error occurred during execution of the UDP_SENDTO/UDP_RECVFROM/TCP_SEND/TCP_RECV instruction. May b...
Page 124 - Stop any other TCP/IP functions operating at the same time.
TROUBLESHOOTING 1-121 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E4025 TCP/IP) Connection aborted. Communication is disconnected during execution of the UDP_SENDTO/UDP_RECVFROM/TCP_CONNECT/TCP_SEND/TCP_RECV/TCP_ACCEPT instruc-tion. May be a p...
Page 129 - Check LED indicator on the interface card, and reset the error.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-126 August 9, 2005 Ka 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 defective hardware. ⇒ Check LED indicator on the interface card, and...
Page 130 - If the error recurs, cycle the controller power OFF and ON.
TROUBLESHOOTING 1-127 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka 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 AnyBus PROFIBUS-DPmaster changed to OFFLINE. ⇒ Use the sub-sub-code XX as a troubl...
Page 131 - Ensure the correct parameters and node address are used.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-128 August 9, 2005 Ka a a w s k ERROR CODE E4525 ABMA-PDP) Timeout of sending message. XX ABMA-PDP module overload, sending message cannot be processed within the allowedtime. ⇒ Check the fieldbus cable and connections, ...
Page 133 - Check the setting in AUX 0605.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-130 August 9, 2005 Ka a a w s k ERROR CODE E5003 Illegal extend (retract) output signal. Occurs when the output signals for the extend and retract operation of a spot weldingapplication are not properly set. ⇒ Check the ...
Page 134 - Incorrect gun number is read due to damaged gun harness.
TROUBLESHOOTING 1-131 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E5007 Servo weld gun not connected or wrong gun connected.(Servo spot weld gun only) Main causes include:1. The robot executes a step when a gun is not attached to the tool chan...
Page 135 - Define the parameters in AUX 1021.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-132 August 9, 2005 Ka a a w s k ERROR CODE E5010 Servo weld gun mechanical parameter is not set.(Servo spot weld gun only) A new gun is connected and the mechanical parameters are not defined in AUX 1021. ⇒ Define the pa...
Page 136 - Incorrect program data is used.
TROUBLESHOOTING 1-133 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E5015 Gun status data disagrees with clamp condition.(Servo spot weld gun only) Incorrect program data is used. Main causes include:1. Clamp ON is taught in a step that includes...
Page 139 - Pressurization comp. signal has not been detected.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-136 August 9, 2005 Ka a a w s k ERROR CODE E5024 Pressurization comp. signal has not been detected. Pressurization completion signal is not received from the weld controller/timer. Main causes include:1. Defective weld c...
Page 140 - Return the system to normal operation and re-execute weld.
TROUBLESHOOTING 1-137 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E5027 Robot stopped during weld.(Spot weld specifications type C)(Servo spot weld gun only) This error occurs when the robot is placed in a HOLD or an E-STOP condition after the...
Page 141 - Replace the copper backing plate.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-138 August 9, 2005 Ka a a w s k ERROR CODE E5030 Copper plate wear exceeds limit. step=XX.(Servo spot weld gun only) The copper backing plate wear exceeds the copper plate wear limit (AUX 1029). Theerror is detected when...
Page 142 - The thickness of the workpiece is out of tolerance.
TROUBLESHOOTING 1-139 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E5033 Cannot weld because of abnormal thickness.(Servo spot weld gun only) The thickness of the workpiece is out of tolerance. Main causes include:1. Defective workpiece.2. Inco...
Page 143 - Signal condition already input.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-140 August 9, 2005 Ka a a w s k ERROR CODE E6002 Signal condition already input. The signal condition is already met when an XDMOVE or XD(2)START move is ex-ecuted and the signal monitoring starts. ⇒ Check input signal t...
Page 144 - Change wrist posture.
TROUBLESHOOTING 1-141 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E6007 Wrist can’t be straightened any more (Singular point 1). The posture of JT5 is set too close to 0 degrees (or a multiple of 360 degrees) on arobot equipped with a 3S type ...
Page 145 - Relative distance between guns is too near.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-142 August 9, 2005 Ka a a w s k ERROR CODE E6012 Relative distance between guns is too near. The gun tips of two networked robots is less than the minimum specified distance for theapplication. ⇒ If this error occurs in ...
Page 147 - Arc weld insulation defect.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-144 August 9, 2005 Ka a a w s k ERROR CODE E6505 Arc weld insulation defect. This error occurs when robot movement causes insulation failure. ⇒ Ensure the welder, torch, and robot insulation are in good working condition...
Page 148 - WS LINEAR SPEED9 TIMER0
TROUBLESHOOTING 1-145 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E6510 Undefined sensing direction.(Touch sensing) Occurs when the step proceeding the WORK_DETECT instruction is not an air_cutpoint. ⇒ Insert an air_cut point in the program be...
Page 149 - (error occurs at this
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-146 August 9, 2005 Ka a a w s k ERROR CODE E6512 Undefined mother or daughter work.(Touch sensing) Main causes include:1. A previous work instruction is not completed before another work instruction is ex- ecuted. 2. Pro...
Page 150 - Occurs when points are taught in incorrect order.
TROUBLESHOOTING 1-147 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E6514 Work specification incorrect.(Touch sensing) Occurs when a previous work instruction is not completed before another work instruc-tion is executed. Example:1. AC JOINT SPE...
Page 151 - did not touch the work within the allowed time.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-148 August 9, 2005 Ka a a w s k ERROR CODE E6516 Wire check failure.(Touch sensing) Main causes include:1. The position of a taught point is recorded too far from the workpiece, and the wire tip did not touch the work wi...
Page 158 - Beyond RTPM tracking ability.
TROUBLESHOOTING 1-155 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE E6538 Beyond RTPM tracking ability. Occurs when the current tracking value exceeds the threshold value and the number oftimes value set for RTPM tracking ability errors. Example...
Page 159 - Beyond AVC tracking ability.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-156 August 9, 2005 Ka a a w s k ERROR CODE E6540 Beyond AVC tracking ability. Occurs when the current tracking value exceeds the threshold value and the number oftimes value set for RTPM tracking ability errors. Main cau...
Page 161 - Not in cooperative mode.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-158 August 9, 2005 Ka a a w s k ERROR CODE E8200 Not in cooperative mode. Cooperative motion instruction is taught before MASTER/SLAVE instruction or afterALONE instruction. ⇒ Use cooperative motion instructions between ...
Page 162 - Input data is too big.
TROUBLESHOOTING 1-159 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k 1.3.2.3 PXXXX OPERATION 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...
Page 164 - Cannot use this command/instruction in current mode.
TROUBLESHOOTING 1-161 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE P0111 Cannot use this command/instruction in current mode. The command/instruction entered could not be executed in the selected mode.Example: “EDIT” is entered in the program e...
Page 166 - Expected to be a binary operator.
TROUBLESHOOTING 1-163 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE P0121 Expected to be a binary operator. A non-binary operator has been entered where a command expected a binary operator. ⇒ Enter a binary operator. ___________________________...
Page 168 - Array variable already exists.
TROUBLESHOOTING 1-165 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE P0131 No. of dimension in array exceeds 3. Attempted to create an array variable with more than 3 dimensions.Example: “point[3,5,7,9]=1” returns an error. ⇒ Use 3 or less dimens...
Page 169 - Local variable expected.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-166 August 9, 2005 Ka a a w s k ERROR CODE P0135 Local variable expected. A global variable is used when defining a temporary argument for a subroutine.Example: “SUB(a)” returns an error. ⇒ Use a local variable when defi...
Page 173 - Time or date is entered in the wrong format.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-170 August 9, 2005 Ka a a w s k ERROR CODE P0153 Illegal clock value. Time or date is entered in the wrong format. ⇒ Re-enter the values correctly; time—military, date—yy/mm/dd. __________________________________________...
Page 174 - Specify ”ON” or “OFF”.
TROUBLESHOOTING 1-171 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE P0158 Missing “BY”. The argument is missing the necessary “BY”.Example: “POINT y = SHIFT (x 5,5,5) ⇒ Ensure command/instruction complies with AS Language syntax and format.Examp...
Page 176 - Cannot execute a program because of EXT.HOLD input.
TROUBLESHOOTING 1-173 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE P1003 Cannot execute a program because of EXT.HOLD input. An attempt to cycle start a program is made while external hold signal is ON. ⇒ Release the external hold and re-execut...
Page 182 - This program is not editable.
TROUBLESHOOTING 1-179 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE P1034 This program is not editable. The auto load measurement program cannot be edited. ⇒ Use a program name that does not include the auto load measurement programname. _______...
Page 193 - Illegal sequence numbers for file I/O data.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-190 August 9, 2005 Ka a a w s k ERROR CODE P2051 Illegal sequence numbers for file I/O data. During data transfer between the 1KA and 1KF boards, the response from the 1KFboard does not conform to the request from the 1K...
Page 194 - A file stored on the 1KA board cannot be opened.
TROUBLESHOOTING 1-191 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE P2055 [LSEQ] Program is already running. During execution of the basic operation part of the sequence function of the KLogicprogram, the program is executed again by the LSQEXEC...
Page 197 - No more data can be registered.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-194 August 9, 2005 Ka a a w s k ERROR CODE P2069 [FDD/PC_CARD] Device already in use. Attempting to perform several processes at the same time to/from the floppy disk/PCcard. The next task is commanded while the previous...
Page 201 - Cannot generate working line direction.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-198 August 9, 2005 Ka 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 directioncannot be determined. ⇒ Ensure the star t and e...
Page 202 - Cannot program reset, because not at home position 1.
TROUBLESHOOTING 1-199 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka 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 program reset signal isignored. ⇒ Ensure the robot is at ...
Page 205 - RAM battery low voltage.
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-202 August 9, 2005 Ka a a w s k ERROR CODE W1010 RAM battery low voltage. Main causes include:1. Backup battery voltage below minimum value (3.3 VDC or less).2. Defective battery harness.3. Defective 1KA board. ⇒ Back up...
Page 206 - Check each harness for short circuit.
TROUBLESHOOTING 1-203 August 9, 2005 D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT Ka a a w s k ERROR CODE W1013 Encoder battery low voltage [Servo (XX)]. Voltage of the encoder back up battery on the 1FG/1HG board decreased to 3.3 volts orless, or the encoder battery alarm signal (B...
Page 213 - TROUBLESHOOTING FLOWCHARTS
TROUBLESHOOTING D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 1-210 August 9, 2005 Ka a a w s k 1.4 TROUBLESHOOTING FLOWCHARTS The following flowcharts are arranged by error code number. Refer also to the corre-sponding error code information in section 1.3.2.2 during troubleshooting...
Page 230 - COMPONENT REPLACEMENT
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-1 Ka 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 AVR, etc., and, units. 2.1 General Safety Precautions on Replacement...
Page 231 - GENERAL SAFETY PRECAUTIONS ON REPLACEMENT
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-2 Ka a a w s k 2.1 GENERAL SAFETY PRECAUTIONS ON REPLACEMENT This section describes the precautions to be taken when replacing parts due to trouble, etc. This information is presented here for use as general precautions. In addition to ...
Page 233 - REPLACEMENT PROCEDURE FOR PARTS IN CARD RACK
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-4 Ka a a w s k 18. Printed boards and power blocks are designed differently for each robot model. Be sure to replace the correct type. 19. When air or water is supplied, shut OFF the supply source and purge any remaining pressure from t...
Page 234 - After completion of data saving, turn OFF the control power.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-5 Ka 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 data to storage media such as PCCARD, FD...
Page 239 - REPLACEMENT PROCEDURE FOR POWER BLOCK UNIT; Four types of power block are available as described below.; DANGER
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-10 Ka a a w s k 2.3 REPLACEMENT PROCEDURE FOR POWER BLOCK UNIT This section describes the replacement procedure for the power block unit mounted in the controller. Four types of power block are available as described below. 1. 1KC: Powe...
Page 240 - Remove all connectors connected to the power block unit.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-11 Ka a a w s k 1. Remove all connectors connected to the power block unit. 2. Loosen the four screws fixing the power block unit to the controller so that the power block unit can be removed from the controller. (These screws are not r...
Page 241 - Remove the screw fixing the earth wired from the power block unit.; Earth
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-12 Ka a a w s k 2.3.3 1KD POWER BLOCK UNIT (FOR D7X CONTROLLER) 1. Remove the controller cover. 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 un...
Page 244 - REPLACEMENT PROCEDURE FOR MC UNIT PARTS (FOR D3X; connected to the MC unit.; Restore the connectors removed in step 1.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-15 Ka a a w s k 2.4 REPLACEMENT PROCEDURE FOR MC UNIT PARTS (FOR D3X CONTROLLER) This section describes the replacement procedure for the MC unit (power supply unit) and the 1KQ board (power circuit board) which flanks the MC unit. 2.4....
Page 245 - CAUTION; Connector
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-16 Ka a a w s k 2.4.2 1KQ BOARD (POWER CIRCUIT BOARD) 1. Remove the MC unit. For details, refer 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 ...
Page 247 - REPLACEMENT PROCEDURE FOR 1NQ BOARD (FOR D7X
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-18 Ka a a w s k 2 .5 REPLACEMENT PROCEDURE FOR 1NQ BOARD (FOR D7X CONTROLLER) This section describes the replacement procedure for the 1NQ board (power circuit board) 1. Turn OFF the control power. 2. Remove the power block unit. (For t...
Page 248 - REPLACEMENT PROCEDURE FOR FAN (FOR D3X CONTROLLER)
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-19 Ka a a w s k 2 .6 REPLACEMENT PROCEDURE FOR FAN (FOR D3X CONTROLLER) Fans are installed for the card rack, the power block unit, and the MC unit. This section describes the replacement procedure for these fans. 2.6.1 FAN FOR CARD RAC...
Page 249 - back. The upper fan cannot be seen from outside.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-20 Ka a a w s k 2 .6.2 FANS ON THE BACK OF CONTROLLER This section describes the replacement procedures for the two fans mounted on the controller back. The upper fan cannot be seen from outside. 2.6.2.1 UPPER FAN ON BACK OF CONTROLLER ...
Page 250 - Remove the six screws fixing the plate on the controller back.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-21 Ka a a w s k 2 .6.2.2 LOWER FAN ON BACK OF CONTROLLER 1. Turn OFF the control power. 2. Remove the six screws fixing the plate on the controller back. 3. Pull out the plate, remove the connector connected to the controller, and remov...
Page 252 - REPLACEMENT PROCEDURE FOR FAN (FOR D7X CONTROLLER); Remove the four screws fixing the fan.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-23 Ka a a w s k 2 .7 REPLACEMENT PROCEDURE FOR FAN (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 thes...
Page 255 - REPLACEMENT PROCEDURE FOR BATTERIES; was pulled out, put it back to the original place.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-26 Ka a a w s k 2.8 REPLACEMENT PROCEDURE FOR BATTERIES This section describes the replacement procedure for the battery provided to backup data. 2.8.1 BATTERY ON 1KA BOARD As backup power supply for SRAM and RTC (Real Time Clock), the ...
Page 256 - Record the encoder value for all axes before replacing a battery.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-27 Ka a a w s k 2.8.2 BATTERY ON 1FG/1HG BOARD 1. Record the encoder value for all axes before replacing a battery. 2. Before replacing the battery, confirm that the new battery has +3.6V or more voltage. 3. Turn OFF the control power. ...
Page 257 - REPLACEMENT PROCEDURE FOR FUSES; This section describes the replacement procedure for the fuses.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-28 Ka a a w s k 2.9 REPLACEMENT PROCEDURE FOR FUSES This section describes the replacement procedure for the fuses. 2.9.1 FUSES ON 1KP BOARD Two types of fuses- Fuse1 and Fuse2- are mounted on the 1KP board. 1. Turn OFF the control powe...
Page 258 - Push in the new fuse, and turn it 90 degrees to the right to install.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-29 Ka a a w s k 2.9.2 FUSES ON 1NQ BOARD (FOR D7X CONTROLLER) 1. Turn OFF the control power. 2. Remove the controller cover. 3. Turn the fuse 90 degrees to the left. Then pull it out and remove the fuse from the board. 4. Push in the ne...
Page 259 - REPLACEMENT PROCEDURE FOR FILTER; procedure described below.
D SERIES CONTROLLER TROUBLESHOOTING AND COMPONENT REPLACEMENT 2-30 Ka a a w s k 2.10 REPLACEMENT PROCEDURE FOR FILTER Wash filters periodically to keep them clean. For replacement, follow the replacement procedure described below. Filters are located on the side and back of the controller. Take the ...
Kawasaki FR651V-AS00
User Manual