Kawasaki MPVDCONTV113E-3 - Manual

Kawasaki MPVDCONTV113E-3

Kawasaki MPVDCONTV113E-3 – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 2 – For additional information contact:
  • Page 3 – REVISION HISTORY; Ka a a
  • Page 4 – TROUBLESHOOTING
  • Page 6 – Figure 1-1 Troubleshooting Process
  • Page 8 – PRELIMINARY TROUBLESHOOTING; D Series
  • Page 9 – Defective F1 circuit breaker.
  • Page 10 – Ensure the 1KP board fuses F1 and F2 are not open.
  • Page 11 – +12 VDC is not supplied to the teach pendant.
  • Page 12 – KA Main CPU Board; Figure 1-3 1KA/Teach Pendant Communication
  • Page 14 – External hold condition exists.; WARNING
  • Page 15 – Table 1-1 provides an explanation of the error code prefixes.
  • Page 16 – Figure 1-4 Teach Pendant Error Screen Display
  • Page 17 – Replace the 1KA board.; Replace the 1KA board.
  • Page 18 – Ensure the correct 1KB board software is loaded into the 1KA board.
  • Page 20 – AS Flash memory sum check error.
  • Page 21 – Cycle the controller power OFF and ON.
  • Page 23 – Replace the AS or servo software.
  • Page 24 – AMP power unit error.
  • Page 26 – Ensure the motor power circuit connector is properly attached.
  • Page 27 – Replace the regenerative unit.
  • Page 28 – regenerative resistor unit.
  • Page 30 – Replace the power block.
  • Page 31 – Error of download of servo data.
  • Page 32 – Encoder misread error JtXX.
  • Page 33 – Defective gun changer connection or encoder comm. error.
  • Page 34 – Ensure the correct AS software is loaded.
  • Page 35 – Check the power line wiring and repair or replace as necessary.
  • Page 36 – Confirm continuity of thermal line.
  • Page 38 – AC primary power OFF.
  • Page 39 – 4VDC power source is too low.
  • Page 40 – Primary power source is too high.
  • Page 41 – Primary power source is too low.
  • Page 42 – Adjust the AVR output voltage.
  • Page 43 – Brake line error for JtXX.
  • Page 46 – Blown fuse on safety circuit emergency line.
  • Page 48 – NOTE
  • Page 52 – No response from the arm ID board.
  • Page 53 – Replace defective 1GS board.
  • Page 58 – Lower byte 3: connect amplifier or motor.
  • Page 67 – ADC input range error.
  • Page 69 – No.2 power sequence board is not installed.
  • Page 72 – Replace serial flash memory on the 1GV board.
  • Page 75 – Safety circuit was cut OFF.
  • Page 76 – ciently between welds.; Servo Spot Weld Gun
  • Page 77 – Check for noise and shield integrity.; For additional information on error code E1029, see section 1.4.
  • Page 78 – Ensure the value set in AUX 0504 is correct.
  • Page 79 – The servo gun or tool changer harness is defective.; For additional information on error code E1032, see section 1.4.
  • Page 80 – Ensure the 1KB board is properly seated into the card rack.; For additional information on error code E1034, see section 1.4.
  • Page 81 – For additional information on error code E1035, see section 1.4.
  • Page 82 – Check for noise malfunction and shield integrity.; For additional information on error code E1036, see section 1.4.
  • Page 83 – This error is caused by abnormal encoder absolute position data.; For additional information on error code E1037, see section 1.4.
  • Page 84 – For additional information on error code E1038, see section 1.4.
  • Page 85 – For additional information on error code E1039, see section 1.4.; Replace the encoder or encoder harness.
  • Page 86 – Set the software limits in AUX 0507 to an appropriate value.
  • Page 88 – Ensure spot weld is selected in AUX 0605-1.
  • Page 90 – Cannot execute motion instruction.
  • Page 93 – Illegal pattern type.
  • Page 97 – Star t point for Jt XX beyond motion range.
  • Page 103 – Lack of system processing time; Spot Welding and Material Handling; Change the posture of the robot.
  • Page 106 – Deviation error of Jt XX.; Main causes include or the following abnormalities:; Inspect the workpiece replace it if necessary.
  • Page 108 – Repair mechanical or electrical failures as necessary.
  • Page 113 – Cannot open setting data, so cannot set to shipment state.
  • Page 114 – Option SIO por t is not installed.
  • Page 115 – Refer to the message displayed after the error message.
  • Page 116 – Buffer overflow occurred gravity comp. value channel XX.
  • Page 117 – If this error recurs, contact KRI customer service.; If error cannot be reset, cycle controller power OFF and ON.
  • Page 118 – Data communication error.
  • Page 122 – Ensure during multiple socket openings do not exceed limits.
  • Page 123 – Check for problems at the target end node and repair as necessary.
  • Page 124 – Stop any other TCP/IP functions operating at the same time.
  • Page 129 – Check LED indicator on the interface card, and reset the error.
  • Page 130 – If the error recurs, cycle the controller power OFF and ON.
  • Page 131 – Ensure the correct parameters and node address are used.
  • Page 133 – Check the setting in AUX 0605.
  • Page 134 – Incorrect gun number is read due to damaged gun harness.
  • Page 135 – Define the parameters in AUX 1021.
  • Page 136 – Incorrect program data is used.
  • Page 139 – Pressurization comp. signal has not been detected.
  • Page 140 – Return the system to normal operation and re-execute weld.
  • Page 141 – Replace the copper backing plate.
  • Page 142 – The thickness of the workpiece is out of tolerance.
  • Page 143 – Signal condition already input.
  • Page 144 – Change wrist posture.
  • Page 145 – Relative distance between guns is too near.
  • Page 147 – Arc weld insulation defect.
  • Page 148 – WS LINEAR SPEED9 TIMER0
  • Page 149 – (error occurs at this
  • Page 150 – Occurs when points are taught in incorrect order.
  • Page 151 – did not touch the work within the allowed time.
  • Page 158 – Beyond RTPM tracking ability.
  • Page 159 – Beyond AVC tracking ability.
  • Page 161 – Not in cooperative mode.
  • Page 162 – Input data is too big.
  • Page 164 – Cannot use this command/instruction in current mode.
  • Page 166 – Expected to be a binary operator.
  • Page 168 – Array variable already exists.
  • Page 169 – Local variable expected.
  • Page 173 – Time or date is entered in the wrong format.
  • Page 174 – Specify ”ON” or “OFF”.
  • Page 176 – Cannot execute a program because of EXT.HOLD input.
  • Page 182 – This program is not editable.
  • Page 193 – Illegal sequence numbers for file I/O data.
  • Page 194 – A file stored on the 1KA board cannot be opened.
  • Page 197 – No more data can be registered.
  • Page 201 – Cannot generate working line direction.
  • Page 202 – Cannot program reset, because not at home position 1.
  • Page 205 – RAM battery low voltage.
  • Page 206 – Check each harness for short circuit.
  • Page 213 – TROUBLESHOOTING FLOWCHARTS
  • Page 230 – COMPONENT REPLACEMENT
  • Page 231 – GENERAL SAFETY PRECAUTIONS ON REPLACEMENT
  • Page 233 – REPLACEMENT PROCEDURE FOR PARTS IN CARD RACK
  • Page 234 – After completion of data saving, turn OFF the control power.
  • Page 239 – REPLACEMENT PROCEDURE FOR POWER BLOCK UNIT; Four types of power block are available as described below.; DANGER
  • Page 240 – Remove all connectors connected to the power block unit.
  • Page 241 – Remove the screw fixing the earth wired from the power block unit.; Earth
  • Page 244 – REPLACEMENT PROCEDURE FOR MC UNIT PARTS (FOR D3X; connected to the MC unit.; Restore the connectors removed in step 1.
  • Page 245 – CAUTION; Connector
  • Page 247 – REPLACEMENT PROCEDURE FOR 1NQ BOARD (FOR D7X
  • Page 248 – REPLACEMENT PROCEDURE FOR FAN (FOR D3X CONTROLLER)
  • Page 249 – back. The upper fan cannot be seen from outside.
  • Page 250 – Remove the six screws fixing the plate on the controller back.
  • Page 252 – REPLACEMENT PROCEDURE FOR FAN (FOR D7X CONTROLLER); Remove the four screws fixing the fan.
  • Page 255 – REPLACEMENT PROCEDURE FOR BATTERIES; was pulled out, put it back to the original place.
  • Page 256 – Record the encoder value for all axes before replacing a battery.
  • Page 257 – REPLACEMENT PROCEDURE FOR FUSES; This section describes the replacement procedure for the fuses.
  • Page 258 – Push in the new fuse, and turn it 90 degrees to the right to install.
  • Page 259 – REPLACEMENT PROCEDURE FOR FILTER; procedure described below.
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D SERIES CONTROLLER

TROUBLESHOOTING AND

COMPONENT REPLACEMENT

MPVDCONTV113E-3

Ka a a

w s k

Kawasaki Robotics (USA), Inc.

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Summary

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 ..................................................................

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