COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

Kawasak
C SERIES CONTROLLER
QUICK REFERENCE TROUBLESHOOTING GUIDE
MPECCTSV112E

Kawasak
Kawasaki Robotics (USA), Inc.
 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted
without the express written permission of Kawasaki Robotics (USA), Inc. The contents
of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical,
electrical, photocopy, facsimile, or electronic data media, without the express written
permission of Kawasaki Robotics (USA), Inc.

All Rights Reserved.

Copyright © 2001, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393

The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.

This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.

KAWASAKI ROBOTICS (USA), INC. TRAINING

Training courses covering operation, programming, electrical maintenance, and me-

chanical maintenance are available from Kawasaki Robotics (USA), Inc. These courses
are conducted at our training facility in Wixom, Michigan, or on-site at the customer’s
location.

For additional information contact:

Kawasaki Robotics (USA), Inc.

Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
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REVISION HISTORY

Revision Release
Number Date Description of Change Initials
0 12/17/02 Initial PDF release, based on rev. 0 of the print copy. JRS/JRS
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INTRODUCTION

I.0 INTRODUCTION ................................................................................................... I-2

I.1 Safety .................................................................................................................... I-2
I.2 Manuals ................................................................................................................. I-3
I.3 Required Items ...................................................................................................... I-3

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INTRODUCTION

I.0 INTRODUCTION

Unit 1 of this manual provides troubleshooting information about certain specific

C controller failures. If one of these failures occurs, repair personnel can use this infor-
mation to quickly:

1. Locate the appropriate troubleshooting information, based on the symptoms

2. Assemble the necessary documentation, special tools, equipment, materials, and
spare parts
3. Review brief theory of operation information
4. Determine the cause of the failure
5. Perform the repair

This manual is a guide only, it is not intended to be the only manual used when trouble-
shooting the C controller; refer to section I.2 for additional Kawasaki manuals that are
required.

Unit 2 provides information about the types of software that are installed on the
C controller, when they need to be installed, and guidelines for software management.

I.1 SAFETY

NOTE
Safety is the most important consideration when using
industrial automated and robotic equipment. For safety
information, refer to the C Series Controller Electrical
Maintenance Manual, MRECCON118E, unit 2, Safety.

In order to safely operate, maintain, and repair the Kawasaki C controller robot system,
personnel must be knowledgeable about the automated, peripheral, and robotic equip-
ment that occupy the safeguarded space. It is recommended that all personnel who
operate, teach, maintain, or repair Kawasaki industrial robots, attend a Kawasaki ap-
proved training course that pertains to their particular job responsibilities.

I-2 December 17, 2002

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INTRODUCTION

I.2 MANUALS

When performing the troubleshooting procedures in this manual, the following Kawasaki
manuals are required:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Electrical Schematics Manual, Vol 1.0 For U-Series Robots
MRESCCON128E1
• C Series Controller Electrical Schematics Manual, Vol 2.0 For F-Series Robots
MRESCCON89E2
• C Series Controller Electrical Schematics Manual, Vol 3.0 For Z-Series Robots
MRESCCON80E3
• C Series Controller Operations and Programming Manual, MROCCONTO87E
• C Series Controller Software Download Procedures, MROCCONTSW78E
• C Series Controller Servo Spot Weld Gun Set Up and Operation, MRVCCSGW31E
• Mechanical Maintenance Manual, for the particular robot model

To order a manual, please contact the Kawasaki Training and Documentation depart-
ment.

Phone: (248) 305-7610 x212

Email: training@kri-us.com

I.3 REQUIRED ITEMS

In order for the repair procedures to be accomplished as quickly as possible, all docu-
mentation, special tools, equipment, materials, and spare parts described in this manual
must be readily available to repair personnel. Each procedure lists special tools that
may be required; in addition to the special tools, a basic tool kit is also required.

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1.0 TROUBLESHOOTING ................................................................................... 1-2

1.1 Type 2 Teach Pendant .................................................................................... 1-3
1.1.1 Blank Screen (Black) ..................................................................................... 1-3
1.1.2 Blank Screen (White) ..................................................................................... 1-7
1.2 1GA/1HA Board CPU Error (-1100) ............................................................... 1-9
1.3 Encoder ....................................................................................................... 1-16
1.3.1 Error -1516 ................................................................................................... 1-16
1.3.2 Error -1517 ................................................................................................... 1-21
1.3.2.1 Servo Spot Weld Gun .................................................................................. 1-23
1.3.3 Error -1553 ................................................................................................... 1-24
1.3.3.1 Servo Spot Weld Gun .................................................................................. 1-30
1.3.4 Error -1555 ................................................................................................... 1-31
1.4 Servo Amplifier ............................................................................................ 1-36
1.4.1 Error -1500 ................................................................................................... 1-36
1.4.1.1 Servo Spot Weld Gun .................................................................................. 1-41
1.4.2 Error -1559 ................................................................................................... 1-42
1.5 1HP Board ................................................................................................... 1-46

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TROUBLESHOOTING

1.0 TROUBLESHOOTING

This unit provides quick reference C Controller troubleshooting information for certain
specific system failures. Please review all procedures and ensure that the following
required items are readily available for all procedures:

• Documentation
• Special tools
• Equipment
• Materials
• Spare parts

NOTE
Failure to maintain the required items, increases the
time required to perform the repair procedure.

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1.1 TYPE 2 TEACH PENDANT

1.1.1 BLANK SCREEN (BLACK)

Symptom:

The type 2 teach pendant (TP) screen is blank (black).

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Software Download Procedures, MROCCONTSW78E
• Digital multimeter
• Type 2 teach pendant (w/harness)
• 8 MB Flash RAM PC card, with TP software

Background:

The TP backlight (Figure 1-1) illuminates the liquid crystal display (LCD). If the backlight
is not illuminated, the screen is dark and the display is not visible. The AVR power
supply (Figure 1-2) supplies +12 VDC to the TP, via the 1HP power circuit control board,
for the TP LCD backlight power supply.

Type 2 Teach Pendant

Backlight
CN CN
Power Emergency Contrast
2 1 Stop Adjustment
Backlight Suppy Switch

Flexible
Circuit Board
CN7 CN4 CN8
CN20

Video
LCD CN6
Board

CN22 CN Controller
1 RS-485

Board A

CN
42 CN Debug
2 RS-485
CN
J1 41
Touch Panel
J2 JM8
CN3 CN5 CN9
T. LOCK
Switch Flash RAM
3-Position 3-Position PC Card
Enabling Enabling
Device Device
(Left) (Right) CN11 CN12
Board B
Soft Key Keypad/LEDs

Figure 1-1 TP Functional Block Diagram

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Possible cause:

• +12 VDC is not being supplied to the TP

• The TP is defective

Action:

1. Verify that the C controller power is ON.

Observe that the the CONTROL POWER indicator (front/left of the C controller
cabinet) is ON.

2. Ensure that TP DIP switch SW1 (located next to the PC card slot) bits 1 and 2 are
set to OFF.

3. Check the +12 VDC AVR power supply; refer to figure 1-2.

a. 1HP LED LD2 (green) is ON.

b. Check 1GA/1HA +12V test points TP1(black)/TP3 (yellow);

+12 VDC ±0.1 VDC.

Continued on page 1-6

1-4 December 17, 2002

 1FS/1HS
(1FS shown)
AVR
Overtravel Limit 1GA/1HA
Power
Switch Override 1GW (1HA shown)
Supply
1HZ (G1)
1HP SLOT6 SLOT5 SLOT4 SLOT3 SLOT2 SLOT1 1GA G1
CN1
1GA/1HA Board LEDs Status
3.6V Lithium Analog Output Vcc, +5 VDC (± 0.05 V) Note: Listed in order from the top to the
CN2 CN1 bottom of the board.
Batteries LD5 green LD3

December 17, 2002

red green
CN3 SW1 LD4 LD3: 1GA/1HA (green)
1HP Board LEDs Status LD3 green OFF: CPU self-test ends with an error
+12 VDC (± 0.1 V) ON: CPU self-test ends without an error
LD1 (Vcc, +5 VDC) green LD2 red
LD2 CN1
LD1 green green LD2: 1GA/1HA (green)
LD2 (+12 VDC) green green AC INPUT
LD5 OFF: during AS system restart
LD101 red –12 VDC (± 0.1 V)
LD3 (–12 VDC) green ON: blinks 1/sec after AS system restart
LD6 green S1 LD1
LD4 (+24 VDC) S2 red LD1: 1GA/1HA (red)
green red
LD7 OFF: normal
These LEDs are located directly behind
NOTE CN2 ON: ACFAIL or CPU error
red 1FS Board LEDs Status
Kawasak

LD8 GND
LD5, LD6, LD7, and LD8. DIP switches 1GA/S2 and 1FS/S1

DSP
DSP
are shown in their default setting. LD5 (CPU Run)

1 2 3 4 5 6 7 8
LD5 (MPWON) Blinks 1.2 sec./cycle 1HA Board Only

1 2 3 4 5 6 7 8
OFF: motor power OFF
OFF
ON: motor power ON OFF LD4 (Error) LD7: 1HA w/Ethernet Option (green)
CN3 OFF: normal
LD6 (SVCN) OFF: no LAN receive
SW1 ON: error
ON: servo control from the 1GB board ON: LAN receiving

CN5

CN4
LD7 LD3 (ControlNet Status) LD5: 1HA w/Ethernet Option (green)
LD7 (SVERR)

CN1
CN2
green ON: during ControlNet
OFF: normal OFF: LAN link not working
LD5 communication ON: LAN link working
ON: servo error from the 1GB board green
ControlNet LD2 (ControlNet Error) LD4: 1HA w/Ethernet Option (green)
LD8 (ERR) OFF: normal
OFF: normal BNC Connectors CN3 OFF: no LAN transmit
ON: error ON: LAN transmit
ON: servo control error, 1HP board LD4
green LD1 (RI/O Status) LD6: 1HA w/Ethernet Option (green)
CN4 CN2 LD6 ON: during RI/O communication OFF: no LAN collision
green ON: LAN collision
LD101 (Watch Dog Timer)
CN2 OFF: normal
ON: error
TROUBLESHOOTING

System Reset
CN1 (1GA)
CN4 CN1

CN7

CN6
CN3
CN4
+5 VDC ADJ

+12 VDC ADJ

TP1 –12 VDC ADJ

CN8 (+24 VDC)
CN9
TP1G

CN10

Figure 1-2 Card Rack

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C SERIES CONTROLLER

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4. Check all TP to 1HP-CN4 connections (Figure 1-3).

a. Check the TP harness X1 connection.

b. Check the 1HP-CN4 connection.

ON OFF

T.LOCK

ENA SHIFT SPEED CNT

1 4
— —
X Rx

2 5
— —
Y Ry CHECK

C Controller
3 6
— —
Z Rz

CL1 CL2

1HP Board REC

1HP-CN4 X1

Figure 1-3 TP to 1HP Board Connections

5. If action items 1–4 check out OK, replace the TP (with harness).

6. Install the TP software; refer to the C Series Controller Software Download Proce-
dures manual.

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1.1.2 BLANK SCREEN (WHITE)

Symptom:

The type 2 teach pendant screen is illuminated, but there is no display (i.e., the screen
is white).

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Software Download Procedures, MROCCONTSW78E
• Type 2 teach pendant, with harness
• Flash RAM PC card with TP, AS, and Servo software, and user programs and robot
data.

Background:

The TP LCD backlight (Figure 1-4) is functioning, but the video signal from the 1GA/1HA
main CPU board is not being received by the LCD, video board, or board A; or the video
signal is not being generated by the 1GA/1HA board.

Type 2 Teach Pendant

Backlight
CN CN
Power Emergency Contrast
2 1 Stop Adjustment
Backlight Suppy Switch

Flexible
Circuit Board
CN7 CN4 CN8
CN20

Video
LCD CN6
Board

CN22 CN Controller
1 RS-485

Board A

CN
42 CN Debug
2 RS-485
CN
J1 41
Touch Panel
J2 JM8
CN3 CN5 CN9
T. LOCK
Switch Flash RAM
3-Position 3-Position PC Card
Enabling Enabling
Device Device
(Left) (Right) CN11 CN12
Board B
Soft Key Keypad/LEDs

Figure 1-4 TP Functional Block Diagram

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Possible cause:

TP board A, video board, or LCD is bad.

Action:

For steps 3, 5, and 6, refer to the C Series Controller Software Download Procedures
manual.

1. Ensure that TP DIP switch SW1 (located next to the PC card slot) bits 1 and 2 are
both set to OFF.

2. Replace the TP.

3. Install TP software.

If the problem still exists, perform steps 4–6.

4. Replace the 1GA/1HA board.

5. Install AS and Servo software.

6. Load user programs and robot data.

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1.2 1GA/1HA BOARD CPU ERROR (-1100)

Symptom:

• The C controller is locked up.

• No error is displayed at the type 2 teach pendant (TP).
• When a PC with KCWIN terminal software is set up, the ‘ERROR ( -1100) CPU
Error (Code=****)’ is displayed.

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Operations and Programming Manual, MROCCONTO87E

• C Series Controller Software Download Procedures, MROCCONTSW78E
• Notebook computer, with Kawasaki KCWIN terminal software
• Null modem cable for PC to C controller connection
• 8 MB (or larger) Flash RAM PC card with robot software (AS and Servo) and
backup data
• Robot data sheet

Background:

The 1GA/1HA main CPU board CPU has stopped. Because the main CPU is locked up,
error information cannot be displayed on the TP; therefore, a PC with KCWIN terminal
software must be used to display and evaluate the error information.

Possible cause:

• Defective AS or Servo software

• Defective 1GA/1HA Board
• Noise (i.e., electromagnetic interference [EMI])

NOTE
It is very important that all C controller software and
backup data be carefully managed. In order to recover
from this error, it may be necessary to reinstall AS and
Servo software and reload all robot programs and data.

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Action:

1. Connect a PC (with KCWIN) to the C controller operation panel X2 PC terminal port

(Figure 1-5). For information about installing KCWIN software, refer to the KCWIN
installation procedure below.

ON OFF

T.LOCK

ENA SHIFT SPEED CNT

1 4
— —
X Rx

2 5
— —
Y Ry CHECK

3 6
— —
Z Rz

CL1 CL2

REC

Operation Panel

ERROR MOTOR POWER

ERROR RESET CYCLE START

Accessory Panel
TEACH REPEAT HOLD RUN

CONTROL POWER
X1 X2 PC Terminal Port
to 1GA/1HA CN1

Figure 1-5 Connecting a PC to the X2 PC Terminal Port

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KCWIN Installation
The following procedure describes installation of KCWIN files on the PC hard
drive:

1. Confirm that the following KCWIN files are on the diskette or CD:

• KCWIN.EXE
• KCWIN.INI
• KCWINE.HLP

2. Copy KCWIN.EXE to the root of C:.

3. Copy KCWIN.INI to the C:\WINDOWS (Windows 98) or C:\WINNT (Windows

2000) directory.

4. Double click on KCWIN.EXE to open the AS Monitor program.

2. Display the error code information.

For example:

Error (-1100) CPU bus error No=1.

Task (Pc01) Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=****** Occurring
place.

3. Determine which board caused the error.

a. I/O BUS ERROR: 1GW/1HW parallel I/O board address error.

b. PSB BUS ERROR: 1HP power circuit control board error.

c. VME BUS ERROR: VME bus address error.

4. Note the error information in steps 2 and 3.

This information is very important to Kawasaki for determining possible software

bugs. Please forward this information to Kawasaki Customer Service.

Continued on the next page

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5. Cycle the C controller power OFF/ON.

If the error occurs again, perform steps 6–28.

6. Set the C controller power to OFF.

NOTE
Before performing the following procedures, ensure that
AS and Servo software and backup data are loaded on
an 8 MB (or larger) Flash RAM PC card and are readily
available.

7. Set 1GA/1HA board DIP switch S2-8 (Figure 1-2) to ON, to display the initializing
options at power up.

8. Set the C controller power to ON.

9. Initialize the controller.

a. When prompted ‘OK to initialize?’, select <1><ENTER>.

b. When prompted ‘Are you sure?’, select <9894><ENTER>.

Entering ‘9894’ clears programs from SRAM and resets the system variables
to their defaults.

10. Select the 1GA/1HA memory size (1 MB).

Enter <0><ENTER>

Allow the controller to complete the power up sequence.

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NOTE
‘Error (-1019) CHECKSUM ERROR in system data’ is
displayed. This error can be ignored at this time; it is
cleared in step 15.

11. Set the C controller power to OFF.

12. Insert the Flash RAM PC card containing the user program and robot data into the
TP PC card slot.

13. Set 1GA/1HA board DIP switch S2 to its default setting.

14. Set the C controller power to ON.

NOTE
‘ERROR (-1019) check sum error in system data’ is indi-
cated when performing a software download or install-
ing a new 1GA/1HA board. To clear this error, perform
step 15.

15. Clear the check sum error using the AS Language CHSUM command or AUX 78
Clear Check Sum Error.

16. At the operation panel, press the ERROR RESET switch.

Continued on the next page

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NOTE
If the robot data cannot be loaded from the Flash RAM
PC card or PC, all data must be manually entered.

17. Load the user program(s) and robot data from the Flash RAM PC card using
AUX 11 PC Card -> Memory (Load), 1-ALL DATA (Figure 1-6).

Figure 1-6 AUX 11 PC Card -> Memory (Load)

18. Confirm that the robot data matches the Robot Data Sheet.

19. Set the time data using the TIME command or AUX 110 Time.

20. In the teach mode, confirm the proper movement of all axes.

21. Using block step programming, record several points and confirm robot motion in
the check mode; save this test program.

22. Select the test program created in step 21; at a slow speed, run the program in the
repeat mode to verify proper operation.

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23. Verify operational programs.

a. Check step through operational programs to determine if they are functioning

correctly.

b. At a slow speed, run operational programs in the repeat mode.

If the C controller is still not functioning correctly or the error occurs again, perform the
following:

NOTE
The current version of the software may be corrupt. It
may be necessary to obtain new software versions.
Consult the Kawasaki Customer Service department.

24. Verify that the correct versions of AS and Servo software are available.

Consult the Kawasaki Customer Service department. Ensure that the correct soft-
ware is assembled and installed on an 8 MB (or larger) Flash RAM PC card.

25. Replace the 1GA/1HA board.

26. Install AS and Servo software; refer to the C Series Controller Software Download
Procedures manual.

27. Reteach all programs.

NOTE
It is very important that a current back up of all pro-
grams and robot data is maintained, so that the system
can be recovered in case of a failure.

28. Back up all robot programs and data.

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1.3 ENCODER

1.3.1 ERROR -1516

Symptom:

‘ERROR ( -1516) Encoder data abnormal jt-x’ is displayed.

x = 1–7 (joint number)

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Electrical Schematics Manual (for the particular robot model,
refer to the Introduction for a list of schematics manuals)
• C Series Controller Operations and Programming Manual, MROCCONTO87E
• C Series Controller Software Download Procedures, MROCCONTSW78E
• Digital multimeter
• (2) 3.6V lithium batteries (Battery Assy., part number 50750-1007)
• Encoder (or complete motor/encoder assembly)
• 1GB servo CPU board
• 1FG/1HG encoder battery board

Background:

This error occurs when the C controller is powered up and the current encoder value is
different than the encoder value that was stored in memory when the controller was
powered down. If this difference is greater than the value set in AUX 43 Encoder Error
Range (Figure 1-7), the error is generated. The AUX 43 value is normally set to approxi-
mately 2.0 degrees; if set to 0.0, error detection is not performed.

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AUX 43 ENCODER ERROR RANGE

JT1 2.0deg
JT2 2.0deg
JT3 2.0deg
JT4 2.0deg
JT5 2.0deg
JT6 2.0deg

RANGE :Rotation 0.1deg -10.0deg

Linear 0.1mm - 100.0mm

F1 F2 F3 F4

PRE DATA

Figure 1-7 AUX 43 Encoder Error Range

During normal operation, the AVR power supply (Figure 1-2) supplies +12 VDC to the
1FG/1HG encoder battery board (Figure 1-8) +5 VDC power supply, via the following:

• 1HZ board CN3

• Signal harness (XHZ-CN3/X3)
• Separate signal harness
• Mechanical unit S1 harness

Separate
Signal Harness
Robot Arm
1GB Board
1GA Board Command Encoder
line
CPU
Data Request +5V (3.6 V from batteries)
CN1–7
CN2
Encoder
Gate Array Data
I/F
X3A

CN8
1HP Board
X3

+5V CN10 Batteries

Power
3.6 V
Supply
+12V from AVR power supply
CN3
1HZ Board 1FG/1HG Board

C Controller
S1 Harness

Figure 1-8 Encoder Power/Signal Block Diagram

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NOTE
The 1FG/1HG encoder battery board is located in the
base of U and Z series robots, and is accessible by re-
moving the robot cable connection panel.

The 1FG/1HG board supplies +5 VDC to the encoders for logic circuits and memory.

When the C controller is powered down, or the mechanical unit is disconnected from the
controller, the two lithium batteries on the 1FG/1HG board supply 3.6 VDC to the encod-
ers to maintain encoder memory.

Possible cause:

• The controller is intialized.

This is normal; the error occurs for all axes.

• The motor/encoder is replaced.

This is normal; the error occurs for the particular joint for which the motor/encoder
was replaced.

• The 1FG/1HG board batteries are low or they are not connected.

In this case, ‘ERROR (-1511) Encoder battery voltage low [Servo (A)]’ may also be
displayed.

• There is a loss of primary power during robot motion.

The C controller stores encoder values just prior to the power loss, but the mechani-
cal unit continues to move slightly, due to its momentum, before the axes brakes
stop the motion completely.

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• The mechanical unit is moved when the C controller power is OFF.

For example, the controller is powered down and a forklift operator crashes into the
upper arm of the mechanical unit, causing JT1 to rotate (i.e., overcoming the JT1
brake). When the controller is powered up, the error occurs.

Action:

1. If the controller has been initialized,

refer to the C Series Controller Software Download Procedures manual for informa-
tion about procedures to perform following initialization.

2. If the motor/encoder has been replaced,

zero the axis. For zeroing procedures, refer to the C Series Controller Electrical
Maintenance Manual.

3. Check the voltage of the encoder batteries.

Check the 1FG/1HG board battery voltage test points.

a. 1FG: TPG(GND)/TP4(BAT)

b. 1HG: TP5(GND)/TP4(BAT)

The value should be +3.6 VDC; if the voltage is < 3.4 VDC, replace the batteries.

4. Check all encoder to 1HZ board harness connections.

a. 1HZ board CN3

b. Separate signal harness, connectors X3/X3A

c. Base of the mechanical unit, S1 harness, connectors X3A and 1FG/1HG-CN8

d. 1FG/1HG board, S2–S7 or JT7 harness (1FG/1HG connectors CN1–CN6 or

XFG-CN7)

Continued on the next page

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5. Replace the following components one at a time and reevaluate the failure status:

NOTE
It is faster to replace the entire motor/encoder assembly,
than it is to replace the encoder alone. To decrease the
repair time, it may be desirable to maintain spares of
complete, prealigned motor/encoder assemblies; and
replace the entire assembly, instead of replacing just the
encoder. For servo spot weld guns, the motor/encoder
are supplied as a complete assembly.

a. Encoder

Refer to the C Series Controller Electrical Maintenance Manual for the en-
coder replacement procedure.

b. 1GB servo CPU board

Check all jumper and switch settings and harness connections.

NOTE
The encoder assembly contains a capacitor that main-
tains memory power for approximately 30 minutes. In
order to maintain the encoder data when replacing the
1FG/1HG batteries or disconnecting the encoder from
the 1FG/1HG board, the batteries must be replaced or
the encoder reconnected within the 30 minutes.

c. 1FG/1HG encoder battery board

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1.3.2 ERROR -1517

For servo spot weld gun information related to this error, refer to section 1.3.2.1.

Symptom:

‘ERROR (-1517) Cannot read encoder value jt-x’ is displayed.

x = 1–7 (joint number)

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Electrical Schematics Manual (for the particular robot model,
refer to the Introduction for a list of schematics manuals)
• Encoder (or complete motor/encoder assembly)
• 1GB servo CPU board

Background:

When the C controller is powered up, the encoder data cannot be read by the
1GB servo CPU board.

Possible cause:

• Encoder data path (Figure 1-9) is disconnected

• Encoder is defective
• 1GB servo CPU board is defective

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Separate
Signal Harness
Robot Arm
1GB Board
1GA Board Command Encoder
line
CPU
Data Request +5V (3.6 V from batteries)
CN1–7
CN2
Encoder
Gate Array Data
I/F

X3A
CN8
1HP Board

X3
+5V CN10 Batteries
Power
3.6 V
Supply
+12V from AVR power supply
CN3
1HZ Board 1FG/1HG Board

C Controller
S1 Harness

Figure 1-9 Encoder Power/Signal Block Diagram

Action:

1. Check all encoder to 1GB servo CPU board harness connections.

a. Encoder to 1FG/1HG board harness

Check the S2–S7 or JT7 harness (1FG/1HG connectors CN1–CN6 or

XFG-CN7); the component checked depends on which encoder indicates an
error.

b. Base of the mechanical unit, S1 harness, connectors X3A and 1FG/1HG-CN8

c. Separate signal harness, connectors X3/X3A

d. 1GB servo CPU board CN2

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2. If action item 1 checks out OK, replace the following components one at a time and
reevaluate the failure status:

NOTE
It is faster to replace the entire motor/encoder assembly,
than it is to replace the encoder alone. To decrease the
repair time, it may be desirable to maintain spares of
complete, prealigned motor/encoder assemblies; and
replace the entire assembly, instead of replacing just the
encoder. For servo spot weld guns, the motor/encoder
are supplied as a complete assembly.

a. Encoder

Refer to the C Series Controller Electrical Maintenance Manual for the en-
coder replacement procedure.

b. 1GB servo CPU board

Check all jumper and switch settings and harness connections.

1.3.2.1 SERVO SPOT WELD GUN

Possible cause:

The gun is physically disconnected from the tool changer, without performing a software
disconnect.

Action:

Physically connect the gun to the tool changer and cycle the controller power OFF/ON.

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1.3.3 ERROR -1553

For servo spot weld gun information related to this error, refer to section 1.3.3.1.

Symptom:

‘ERROR (-1553) Encoder response error jt-x’ is displayed.

x = 1–7 (joint number)

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Electrical Schematics Manual (for the particular robot model,
refer to the Introduction for a list of schematics manuals)
• Encoder (or complete motor/encoder assembly)
• 1GB servo CPU board

Background:

This error is generated when the encoder data line to/from the 1GB board is discon-
nected or there is noise (i.e., electromagnetic interference [EMI]); or the encoder data
request from the 1GB board to the encoder is not functioning correctly.

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Possible cause:

• Encoder data line (Figure 1-10) is disconnected

• Encoder is defective
• Noise (i.e., electromagnetic interference [EMI])
• 1GB servo CPU board is defective

Separate
Signal Harness
Robot Arm
1GB Board
1GA Board Command Encoder
line
CPU
Data Request +5V (3.6 V from batteries)
CN1–7
CN2
Encoder
Gate Array Data
I/F

X3A
CN8
1HP Board

X3
+5V CN10 Batteries
Power
3.6 V
Supply
+12V from AVR power supply
CN3
1HZ Board 1FG/1HG Board

C Controller
S1 Harness

Figure 1-10 Encoder Power/Signal Block Diagram

! CAUTION
Following these maintenance procedures, when oper-
ated in the automatic mode, the robot can perform un-
predictably—damage to the robot or safeguarded space
equipment can occur. After performing these mainte-
nance procedures, check step through the programs at
a slow speed to verify that the controller is functioning
correctly.

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NOTE
Refer also to the flow chart at the end of this section
(Figure 1-11).

Action:

1. Reset the error.

2. Cycle the C controller power OFF/ON.

3. Check all encoder to 1GB board harness connections (Figure 1-10).

a. Encoder to 1FG/1HG board harness

Check the S2–S7 or JT7 harness (1FG/1HG connectors CN1–CN6 or XFG-

CN7); the component checked depends on which encoder indicates an error.

b. Base of the mechanical unit, S1 harness, connectors X3A and 1FG/1HG-CN8

c. Separate signal harness, connectors X3/X3A

d. 1GB board CN2

4. Check 1GB board jumper and switch settings.

If the 1GB has just been replaced, it’s possible that jumpers and switches were not
correctly set; refer to the C Series Controller Electrical Maintenance Manual.

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NOTE
It is faster to replace the entire motor/encoder assembly,
than it is to replace the encoder alone. To decrease the
repair time, it may be desirable to maintain spares of
complete, prealigned motor/encoder assemblies; and
replace the entire assembly, instead of replacing just the
encoder. For servo spot weld guns, the motor/encoder
are supplied as a complete assembly.

5. Replace the encoder (or the entire motor/encoder assembly, see note above).

Refer to the C Series Controller Electrical Maintenance Manual for the encoder
replacement procedure.

6. Replace the 1GB board.

Check all jumper and switch settings and harness connections.

7. Replace the 1FG/1HG board.

8. Evaluate potential EMI problems.

Check for electrical noise that may be induced into the encoder signal path. Check
all cable shielding.

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Error 1553

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Check connections at the Yes Does the error

encoder connector reoccur?

No
Check connections on the
1FG board
END

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Figure 1-11 Error -1553 Flowchart

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Replace 1GB board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-11 Error -1553 Flowchart (Continued)

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1.3.3.1 SERVO SPOT WELD GUN

Possible cause:

The gun or tool changer encoder harness is defective.

Action:

Inspect the gun (and tool changer, if applicable) encoder harness(es); replace if neces-
sary.

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1.3.4 ERROR -1555

Symptom:

‘ERROR (-1555) Encoder data conversion error jt-x’ is displayed.

x = 1–7 (joint number)

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Electrical Schematics Manual (for the particular robot model,
refer to the Introduction for a list of schematics manuals)
• Encoder
• 1GB servo CPU board
• 1FG/1HG encoder battery board

Background:

This error occurs when there is an M-code pattern data error.

Possible cause:

• Defective encoder
• Encoder data path (Figure 1-12) is disconnected
• Defective 1GB servo CPU board
• Defective 1FG/1HG encoder battery board
• Noise (i.e., electromagnetic interference [EMI])

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Separate
Signal Harness
Robot Arm
1GB Board
1GA Board Command Encoder
line
CPU
Data Request +5V (3.6 V from batteries)
CN1–7
CN2
Encoder
Gate Array Data
I/F

X3A
CN8
1HP Board

X3
+5V CN10 Batteries
Power
3.6 V
Supply
+12V from AVR power supply
CN3
1HZ Board 1FG/1HG Board

C Controller
S1 Harness

Figure 1-12 Encoder Power/Signal Block Diagram

! CAUTION
Following these maintenance procedures, when oper-
ated in the automatic mode, the robot can perform un-
predictably—damage to the robot or safeguarded space
equipment can occur. After performing these mainte-
nance procedures, check step through the programs at
a slow speed to verify that the controller is functioning
correctly.

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NOTE
Refer also to the flow chart at the end of this section
(Figure 1-13).

Action:

1. Replace the encoder.

2. Replace the 1GB servo CPU board.

Check all jumper and switch settings and harness connections.

3. Check all encoder to 1GB board harness connections (Figure 1-12).

a. Encoder to 1FG/1HG board harness

Check the S2–S7 or JT7 harness (1FG/1HG connectors CN1–CN6 or

XFG-CN7); the component checked depends on which encoder indicates an
error.

b. Base of the mechanical unit, S1 harness, connectors X3A and 1FG/1HG-CN8

c. Separate signal harness, connectors X3/X3A

d. 1GB board CN2

4. Replace the 1FG/1HG board.

5. Evaluate potential EMI problems.

Check for electrical noise that may be induced into the encoder signal path. Check
all cable shielding.

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Error 1555

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Replace encoder Yes Does the error

reoccur?
Yes
No
Does No
problem still END
exist?

Yes

Replace 1GB board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Figure 1-13 Error -1555 Flowchart

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Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-13 Error -1555 Flowchart (Continued)

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1.4 SERVO AMPLIFIER

For servo spot weld gun information related to this error, refer to section 1.4.1.1.

1.4.1 ERROR -1500

! CAUTION
Even if this error clears, if it occurs frequently, the AC
servo motor windings can be damaged.

Symptom:

‘ERROR (-1500) Motor overload jt-x’ is displayed.

x = 1–7 (joint number)

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Electrical Schematics Manual (for the particular robot model,
refer to the Introduction for a list of schematics manuals)
• Mechanical Maintenance Manual for the particular robot model
• Digital multimeter
• Reduction units for all axes. For special tools and equipment required for replacing
reduction units, refer to the appropriate Mechanical Maintenance Manual.
• 1GC/1GD/1JK power block
• 1GB servo CPU board
• AC servo motor, with encoder

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Background:

This error is generated when the motor current exceeds the maximum current vs. time
rating (Figure 1-14) threshold.

Motor Current Overload

Continuous
Current
Rating
Time

Figure 1-14 Motor Current vs. Time

For the following information, refer to figure 1-15.

1. Motor current is sensed by the 1GC/1GD/1JK power block current sensors.

2. This current is converted to a voltage and scaled by the 1GM board.
3. The scaled voltage is processed and analyzed by the 1GB servo CPU board.
4. Error processing is performed by the 1GB board and error data is sent to the
1GA/1HA board.

Possible cause:

Mechanical

• The robot impacts an object.

• The robot arm is snagged. For example, a servo spot weld gun cable snags on the
tip dress station as the robot moves away from the tip dress station, preventing it
from moving to the next position.
• Damage to or misalignment of the gears, bearings, or reduction units.
• The payload is exceeded.
• The robot is not capable of executing the taught program. This may be due to
speeds that are too fast and/or path geometry that causes excessive inertial forces.
• The brake is not released.

Continued on page 1-39

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1-38

1GB Board Servo Amp PWM 1GC/1GD/1JK Power Block

Harness A/B

Kawasak
Servo Software Gate Array
KId PU1
VUCMD
IdCMD PU2
=0 d-q to

CN12–CN13
1GA/1HA Board

PV1

CN8–CN9
3- VVCMD PWM Dead Time Photo
1HZ Board

KP KV KIq Buffer PV3

Phase Generator Generator Coupler
PCMD VCMD IqCMD Conv. PW1
CN1
CN4

VWCMD PW2

Position Velocity Phase CL PWM

Id Iq Shut
Power
Calculate Calculate Calculate 3-Phase Error Block Base Amp
Position Velocity Phase to d-q Error Error Information Protection Errors
Data Data Data Conv. Operation
Logics DCOC, 12V

TROUBLESHOOTING
100V, HV
Iu Iv Iw OC
Calculate
M-Code to Binary W-Phase OC, CL Power
Convert Current Detector Transistor
Module

1GM Board U V W
Iu VIU iIU
Current Sensors

CN9–CN11
± 7.5

CN1–CN7
A/D Sample I/V
& Hold to +5 VIV Conv.
Iv Conv. Scaler iIV

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Motor
Harness
Encoder I/F Logics Servo Motor
TxD RS-485
Encoder Absolute Data (M-Code) Request Signal Generator Line
and Rotation Data RxD Driver,
Serial to Parallel Converter
Receiver

CN2

X3
C Controller
Encoder Serial

C SERIES CONTROLLER
December 17, 2002

Communication
Data Line H20/M21

X3A
H32KT/M30KT
Encoder
Separate Signal Harness

Mechanical Unit

Figure 1-15 Current Sensor Feedback

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Electrical

• The motor power path is interrupted (Figure 1-15).

• The brake circuit is open (Figure 1-16); 24 VDC is required to release the brakes.
• The 1GC/1GD/1JK power block is defective.
• The 1GB servo CPU board is defective.
• The AC servo motor is defective.

Mechanical Unit

JT1
BRAKE

4 X105 1

Machine Harness, M2
For the explosion-proof
X5A C controller, +24 VDC
2 1
is routed to the brakes via
the 1LU board.
Separate Harness, Motor B

2 X5 1
Controller
Motor Harness B

1LU

Brake
CN6 9 1 Release
1GB Switch
1HY TP1 JT1
CN1 CN2 CN4 CN5
TB1-2 N BR24G R1 D1
Y20 A2 3 3 1
CR1 TP2 220
24
T1 V1 VDC 2 K3
2 C2
8
(26 VAC) F5 (12 A) 4700 pF
P A1 K3 BR24V
9
X20 1 1
4 3
Solid
State U1
CR1 Relay
2 1
Vcc
CN4
RA19
1 8
1 10 12
CP69 470 18
0.1 m F
U34
19 2
4 18 20 /BRK REQ
CN3

24 VDC

1HP

Figure 1-16 24 VDC Routing to the Brakes

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Action:

1. Check the reduction unit.

2. Check the program.

If the program is new, evaluate the motion. If the end-effector is near the robot’s
maximum payload capacity, the speed is high, or the motion includes drastic
changes in direction, the motor current can be exceeded and error -1500 gener-
ated.

3. Check harness connections; refer to figures 1-15 and 1-16.

4. Replace the following components one at a time and reevaluate the failure status:

NOTE
To save time, it may be desirable to replace the entire
servo amplifier assembly (i.e., 1GB servo CPU board
[with 1GM board] and the 1GC/1GD/1JK power block).

a. 1GB board (with 1GM current sensor feedback board)

b. 1GC/1GD/1JK power block

c. AC servo motor, with encoder

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1.4.1.1 SERVO SPOT WELD GUN

Possible cause:

• The clamp time is too long.

• The distance between weld points is short; the motor does not have enough time to
cool sufficiently between welds.
• The current required to achieve the clamping force setting, exceeds the motor’s
capacity.

Action:

1. If the weld points are close to each other, set a time delay for each weld point. This
provides a cool-down period between welds.

2. Set the clamping force lower; refer to the gun manufacturer’s specifications.

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1.4.2 ERROR -1559

Symptom:

‘ERROR (-1559) Power module error jt-x’ is displayed.

Required documentation, special tools, equipment, materials, and spare parts:

• C Series Controller Electrical Maintenance Manual, MRECCON118E

• C Series Controller Electrical Schematics Manual (for the particular robot model,
refer to the Introduction for a list of schematics manuals)
• Digital multimeter
• Servo amplifier assembly (1GC/1GD/1JK power block and 1GB servo CPU board
[with 1GM current sensor interface])
• AC servo motor
• Fans (part number 60376-1025)

Background:

For the following discussion, refer to figure 1-17.

An error condition exists in one of the 1GC/1GD/1JK power block intelligent power
modules (IPMs); this condition is sensed by one of the corresponding hybrid integrated
circuits (HICs) and an IPM error signal (ERR) is generated and output to the 1GB servo
CPU board. The 1GB board processes this error signal and outputs an error signal
(SVER) to the 1GA main CPU board for processing and display on the TP.

NOTE
Because the Servo software is installed on the 1GA/
1HA main CPU board, and is downloaded to the 1GB
servo CPU at power up, Servo software does not need
to be installed following a servo amplifier replacement.

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1GC/1GD/1JK Board
P IPM
IGBT IGBT IGBT
Servo Motor
Control Control Control CS U
IC IC IC

Uø CS
Vø Wø
IGBT IGBT IGBT
V W
Control Control Control
IC IC IC

+15 VDC H20/M21

Servo Amp PWM
Encoder
Harness A/B
+12 VDC
1GB
CN8/9 PWM HIC
CN12/13
IPM Error (ERR)
1GB
CN9–11 CN1–7 Current Feedback
Separate Signal Harness Encoder Signal

Figure 1-17 1GC/1GD/1JK Board IPM Error Output

Possible cause:

• Defective 1GC/1GD/1JK power block

• Defective 1GB servo CPU board
• Motor U, V, or W phase short-circuit
• Cooling fan(s) not functioning
• Defective servo amp PWM harness A/B

Action:

1. Replace the servo amplifier assembly, which includes the following:

a. 1GC/1GD/1JK power block

b. 1GB servo CPU board (with 1GM current sensor interface).

2. Check for a short-circuit in the motor circuit (Figures 1-18 through 1-20); for detailed
wiring harness diagrams, refer to the appropriate C Series Controller Electrical
Schematics Manual.

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Motor
Harnesses

SERVO AMP
XM1-SA
POWER BLOCK MAJOR
MOTOR
XM2-SA
X4

XTH
1GC/1GD XM3-SA
MINOR
MOTOR
X5

Servo Amp

CN8

CN9
XSOL
Harness A/B

CN9
CN13

CN10
CN12

CN11
CN4 CN6

SIGNAL
CN2
X3

XEPV
1GB
CN5

CN1
1GM
CN8

Figure 1-18 Servo Amplifier Motor Outputs

ON

OFF

CN3 CN4 CN1 CN5

CN7
CN8

CN1 CN13
HOUR METER
h

CN2
CN12

CN4

CN6 CN10

CN9
CN5

CN2 M1 M2 M3

X3 X4 X5
X5A
X4A

X3A

Figure 1-19 Separate Harnesses

1-44 December 17, 2002

December 17, 2002
Kawasak
TROUBLESHOOTING

Figure 1-20 ZT/ZX165 Machine Harness Interconnection Diagram

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C SERIES CONTROLLER

1-45
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1.5 1HP BOARD

This section provides a brief overview of 1HP board functions, it does not provide proce-
dures for specific errors or failures. For detailed information about the 1HP board, refer
to the C Series Controller Electrical Maintenance Manual, MRECCON118E.

The 1HP board (Figure 1-21) performs the following:

• Controls the C controller power up sequence.

• Controls distribution of +24 VDC to relays on the 1HY board; the 1HY relays, in turn,
control distribution of +24 VDC to the K1 and K2 contactors for repeat and teach
modes of operation.
• Provides safety circuits (Figure 1-22).
• Routes 24 VDC to the brakes (Figure 1-23).
• Provides a point of connection between the type 2 teach pendant (TP) and the
1GA/1HA board.
• Monitors the AVR power supply output.
• Provides +24 VDC AVR power supply test points TP1/TP1G (Figure 1-2)
• Fuse F2 (User Interface), circuit protection for I/O +24 VDC (Figure 1-21).

NOTE
When performing troubleshooting procedures related to
the 1HP board, be aware that there may be many con-
nections to the 1HP safety circuits, via XHP-CN1 and
TB2/CJ44 (Figure 1-22), from external safety devices
(e.g., E-stop, safety fence, trigger, and gate box
switches).

1-46 December 17, 2002

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SW1
Overtravel
Limit Switch
Override
LD5 LD1

LD6 LD2

LD7 LD3
P1
LD8 LD4

CN1
(LOWER)
CN2

OFF
ON
(UPPER) 1
DSW1
4

4A 1A
JP2
F2 4B 1B
User
Interface

CN3
(LOWER)
CN4
(UPPER)
P2

3 2 1
JP1
6 5 4
TP1

+24V F3
Safety F1
TP1G

+24G Circuit Safety

Circuit

Kawasak 1HP-50

Figure 1-21 1HP Board Layout

December 17, 2002 1-47

1-48
Operation Panel
E-Stop REPEAT/TEACH Switch
(TEACH position shown)

A1 B1 A2 B2 A3 B3 A4 B4 B5 A5 XR-SW1

5 6 7 8 13 14 15 16 18 17 XHP-CN2
1HP 1HY
+24 XHP-CN3 XHY-CN4
Vcc 4 CR1
VDC
4 1 CR2 CR2 CR3 CR3 XHY-CN3
34 33 14 13 23 24 43 44 K1ON K2
RY2 RY2 5 2 NO COM NO COM NO
A2 K1
CR2 COM NO COM 21 22 A1(+) A1(-)
RY2 6 4 B2
34 33 14 13 23 24 43 44 K2ON K1

LS1-N*
LS2-P*
7 5 CR3 NO COM NO COM NO COM NO COM
A4 21 22 A1(+)
K2
A1(-)
8 6 CR3 CR3 CR4 CR4 B4
F1 1 +24 VDC K1
External 9 7 A5 13 14

0.3 A
CR4

/+24VON
10 8 B5 CND-K1
E-Stop 2
+24 VDC K2
+24 17 9 A6

SW1**
TB2 XHP-CN1 13 14
VDC 18 10 B6 CND-K2
5 5
Kawasak

19 11
6 6
20 12 XHY-CN1
7 7
8 8 A1 BRK-P
F3 3 4 CR1
3 B1 210 VAC

0.3 A
9 9 NO COM

LS1-P*
LS2-N*
10 10 A2 BRK-N
11 11 B2 0 VAC
+24 A3
12 12 VDC
15 13 B3
Safety Fence A4

RY3
RY4
RY4
16 14 5
6 B4
17 15
18 16 A5 +24 VDC
21 21 7 Vcc Vcc B5 +24 VDC GND
22 22 A6 +24 VDC
23 23 B6 +24 VDC GND
RY3 RY4
24 24 8 1 3 2 XHY-CN2 2 3 1 XHY-CN8
25 25 10
External Trigger 26 26
27

/STG-B
/STG-A
27 9
TROUBLESHOOTING

28 28

Figure 1-22 Safety Circuit

43 31 K3
13 14
12 11 13 14 15 16 17 18 XHP-CN4 K3 K3 K3
44 32
Customer Connections***
12 11 17 18 13 14 19 20 X1

Type 2 CN1 B6 A6 A9 B9 A7 B7 A10 B10

XGB-CN4
Teach 1 3 2 1 2 3 4 X1-SA
CN4 1 2 3 4 1GB 1GB
Pendant CN10
1 2 1 2 CN12
1 2 3 4 CN5 BR24V PC3 CN13B
CN9
XGB-CN5 BR24G 9 9 /MSON
8 10 10
9 11 11 +24 VDC
12 12 +24 VDC GND

MSON+
E-Stop Enabling Devices 19 19 Vcc
SSR1 MSON- /MSCNT
Notes: 20 20

*LS1/LS2 limit switch circuits - see Figures 4-6 through 4-9 for more detail
1GC/1GD
**SW1 limit switch override switch is located at the top front of the 1HP board
***Customer Connections - example only. See Figures 4-3 and 4-4, or interface drawings, for more detail POWER BLOCK
C SERIES CONTROLLER

December 17, 2002

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Mechanical Unit

JT1
BRAKE

4 X105 1

Machine Harness, M2
For the explosion-proof
X5A C controller, +24 VDC
2 1
is routed to the brakes via
the 1LU board.
Separate Harness, Motor B

2 X5 1
Controller
Motor Harness B

1LU

Brake
CN6 9 1 Release
1GB Switch
1HY TP1 JT1
CN1 CN2 CN4 CN5
TB1-2 N BR24G R1 D1
Y20 A2 3 3 1
CR1 TP2 220
24
T1 V1 VDC 2 K3
2 C2
8
(26 VAC) F5 (12 A) 4700 pF
P A1 K3 BR24V
9
X20 1 1
4 3
Solid
State U1
CR1 Relay
2 1
Vcc
CN4
RA19
1 8
1 10 12
CP69 470 18
0.1 m F
U34
19 2
4 18 20 /BRK REQ
CN3

24 VDC

1HP

Figure 1-23 24 VDC Routing to the Brakes

December 17, 2002 1-49

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SOFTWARE

2.0 SOFTWARE ......................................................................................................... 2-2

2.1 Hardware/Software Dependency .......................................................................... 2-2
2.2 Software Management Guidelines ........................................................................ 2-3

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SOFTWARE

2.0 SOFTWARE

This unit explains when particular types of C controller software (Figure 2-1) are in-
stalled and provides guidelines for managing the software. For information about how to
install C controller software, refer to the C Series Controller Software Download Proce-
dures manual, MROCCONTSW78E.

Table 2-1 C Controller Software Overview

Software
Type Description Installed To Comments

TP Teach pendant, display and Type 2 teach pendant (TP), Because AS and TP software types/versions
touch panel processing board A may be different, a teach pendant from one
system may not be compatible with another
system.

AS Controller operating system 1GA/1HA main CPU board Before replacing the 1GA/1HA board, ensure
that all user programs and robot data are
backed up.

Servo Servo system 1GA/1HA main CPU board This software is automatically downloaded from
the 1GA/1HA board to the 1GB servo CPU
board at power up. If the 1GB board is
replaced, Servo software does not need to be
reinstalled.

FS Remote I/O and RS-485 or 1FS/1HS board

ControlNet

2.1 HARDWARE/SOFTWARE DEPENDENCY

Table 2-2 shows the software types that need to be installed when a particular hardware
component is replaced. If any other C controller component is replaced, it is not neces-
sary to reinstall software.

Table 2-2 Hardware/Software Dependency

Replaced Component Software to Install

Type 2 Teach Pendant TP

1GA/1HA Main CPU Board AS, Ser vo

1FS/1HS Remote I/O or ControlNet Board FS

2-2 December 17, 2002

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SOFTWARE

2.2 SOFTWARE MANAGEMENT GUIDELINES

It is very important that C controller software be carefully managed; table 2-3 provides
guidance on C controller software management. For a description of currently installed
C controller software at your facility, refer to current documentation. Refer to figure 2-1
for an example of C controller software that can be installed.

Table 2-3 Software Management Guidelines

Subject Explanation

Management Due to the numerous software types and versions, it is very impor tant that the
software and the documentation for the software be carefully managed.

Documentation For ever y C controller in the facility, document the software (i.e., file names and
complete descriptions) that is currently installed.

Personal Computer Copies—ensure that copies of all types and versions of the C controller
software that are used throughout the facility are saved to a PC, and that these
files are well managed, organized, and documented.

Flash RAM—the PC that is used to store C controller software must have a

flash RAM PC card slot, so that software can be quickly loaded on flash RAM
PC cards for subsequent installation on C controllers.

Accessible—the PC that is used to store C controller software must be easily

accessible to all personnel that are required to install software.

Installation Order When loading all software types, load the software in the following order:

1. TP
2. AS
3. Servo
4. FS

Dependency TP, AS, and FS software versions must be compatible with each other.

Each software type (TP, AS, Servo, and FS) can be loaded separately.

AS and Servo software can be downloaded at the same time.

Servo software must be matched with the robot model (e.g., UX150, ZT200,
ZX300, etc.) and application (e.g., spot welding, sealing, or arc welding).

If uncer tain about compatibility, consult Kawasaki Customer Service.

December 17, 2002 2-3

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2-4
1
These files are shown as an example only. For actual installed software, consult current documentation.

Kawasak
AS - 1GA/1HA Main CPU TP - Teach Pendant Servo - 1GB Servo CPU Servo - 1GF Traversing 8th Axis PLC
UX-UB-Series UX-UB-Series; ZX-ZT-Series UX-UB-Series
Material Handling/Servo Gun Material Handling/Servo Gun. UB150 Material Handling/Servo Gun./Sealing UX150
UB150 UB150 A13BJ13 F12EA02 CCL400
4D310KIE (TYPE 2) TD310KHE (TYPE 2) A10BJ12
FS020
Figure 2-1 1Example C Controller Software

UX150 UX150 UX150 (TYPE 1) CCL402

4D580KIE (TYPE 1) TD580KHE (TYPE 1) A13YG14
2D010KDE (TYPE 1) TD010K3E (TYPE 1) B0EYG30

F-Series ZX165 UX200

Sealing TD310KHE (TYPE 2) B0EYM30
FS020 TD580KHE (TYPE 1)
3D430PKE TD400P4E (TYPE 1) ZX-ZT-Series
3D4F0PVE ZX165U

SOFTWARE
ZT200S B13WD13
AS - MAIN CPU (1HA) TD310KHE (TYPE 2)
ZX-ZT Series
Material Handling/Servo Gun. ZX200S ZX165U (TYPE 1)
ZX165 TD310KHE (TYPE 2) B13WD13
4D310KIE (TYPE 2)
4D580KIE (TYPE 1) ZX300S

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4D400P8E (TYPE 1) TD310KHE (TYPE 2) ZT200S
B12W411
ZT200S F-Series
4D310KIE Sealing
FS020 ZX200S
ZX200S TD430PCE B12WE11
4D310KIE TD430PKE

ZX300S ZX300S
4D310KIE B12WH11

C SERIES CONTROLLER
December 17, 2002

F-Series
FS020
B5AF101
B5CF102
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INDEX

INDEX .......................................................................................................................... 7-2

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INDEX

Symbols
1FG Board, 1-16, 1-17, 1-18, 1-19, 1-20, 1-22, 1-26, 1-31, 1-33
1FG/1HG-CN8, 1-22, 1-26, 1-33
1GA Board, 1-4, 1-7, 1-8, 1-9, 1-12, 1-13, 1-15, 1-37, 1-42, 1-46
1GB Board, 1-16, 1-20, 1-21, 1-22, 1-23, 1-24, 1-25, 1-26, 1-31, 1-33, 1-37, 1-39, 1-40, 1-42, 1-43
1GB-CN2, 1-33
1GC Board, 1-37, 1-39, 1-40, 1-42, 1-43
1GD Board, 1-37, 1-39, 1-40, 1-42, 1-43
1GM Board, 1-37, 1-40, 1-42, 1-43
1GW Board, 1-11
1HA Board, 1-4, 1-7, 1-8, 1-9, 1-12, 1-13, 1-15, 1-37, 1-46
1HG Board, 1-16, 1-17, 1-18, 1-19, 1-20, 1-22, 1-26, 1-31, 1-33
1HP Board, 1-3, 1-4, 1-6, 1-46, 1-47
1HW Board, 1-11
1HY Board, 1-46
1HZ Board, 1-17, 1-19
1JK Board, 1-37, 1-39, 1-40, 1-42, 1-43
3.6V Lithium Batteries, 1-16

A
AS Language, 1-13
AS Monitor Program, 1-11
AS Software, 1-7, 1-8, 1-9, 1-15
Automatic Mode, 1-25, 1-32
AUX 11 PC Card -> Memory (Load), 1-14
AUX 110 Time, 1-14
AUX 43 Encoder Error Range, 1-16
AUX 78 Clear Check Sum Error, 1-13
AVR Power Supply, 1-3, 1-4, 1-17, 1-46

B
Back Up, 1-15
Backlight, 1-3, 1-7
Backlight Power Supply, 1-3
Backup Data, 1-9
Batteries, 1-16, 1-18, 1-20
Bearings, 1-37
Block Step Programming, 1-14
Board A, 1-7, 1-8
Brake Circuit, 1-39
Brakes, 1-39, 1-46, 1-49

C
Cable Connection Panel, 1-18
Capacitor, Encoder, 1-20
Card Rack, 1-5
Check Mode, 1-14
Check Step, 1-25, 1-32
Check Sum Error, 1-13
CHECKSUM ERROR, 1-13
CHSUM Command, 1-13

IN-2 December 17, 2002

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INDEX

CJ44, 1-46
CN1-CN6, 1-19
CN1-CN6, 1FG/1HG, 1-22, 1-26, 1-33
CN2, 1-26, 1-33
CN2, 1GB board, 1-22
CN4, 1HP, 1-6
CN8, 1-33
CN8, 1FG/1HG, 1-22, 1-26
CONTROL POWER Indicator, 1-4
Cooling Fan, 1-43
Corrupt Software, 1-15
Current Sensor, 1-37, 1-38

D
Digital Multimeter, 1-3, 1-16, 1-36
Documentation, I-2, I-3

E
E-stop Switch, 1-46
Electromagnetic Interference (EMI), 1-9, 1-24, 1-25, 1-31
EMI, 1-25, 1-27, 1-33
Encoder, 1-16, 1-18, 1-19, 1-20, 1-21, 1-22, 1-23, 1-24, 1-26, 1-27, 1-31, 1-33
Encoder Battery, 1-19
Encoder Battery Board, 1FG/1HG, 1-17
Encoder Data Line, 1-21, 1-25, 1-31
Encoder Memory, 1-18
Encoder Power/Signal, 1-22, 1-25, 1-32
Encoders, 1-18
Equipment, I-2, I-3
ERR, 1-42
ERROR (-1019) check sum error in system data, 1-13
ERROR (-1511) Encoder battery voltage low, 1-18
ERROR (-1517) Cannot read encoder value jt-x, 1-21

F
F2, 1-46
Flash RAM PC Card, 1-3, 1-7, 1-9, 1-14, 1-15

G
Gate Box, 1-46
Gears, 1-37

H
Hardware, 2-2
HIC, 1-42
Hybrid Integrated Circuit (HIC), 1-42

I
I/O +24 VDC, 1-46
I/O BUS ERROR, 1-11

December 17, 2002 IN-3

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INDEX

Impact, 1-37
Inertia, 1-37
Inertial Force, 1-37
Intelligent Power Module (IPM), 1-42
IPM, 1-42

J
JT7 Harness, 1-19, 1-22, 1-26, 1-33
Jumper, 1-20, 1-23
Jumpers, 1-26

K
K1, 1-46
K2, 1-46
Kawasaki Customer Service, 1-11, 1-15
KCWIN, 1-9, 1-10
KCWIN.EXE, 1-11
KCWIN.INI, 1-11
KCWINE.HLP, 1-11

L
LCD, 1-7, 1-8
Liquid Crystal Display (LCD), 1-3

M
M-Code, 1-31
Machine Harness, 1-45
Materials, I-2, I-3
Memory, 1-16
Motor, 1-19, 1-21, 1-23, 1-27, 1-37, 1-39, 1-40, 1-42, 1-43
Motor Current, 1-37, 1-40

N
Noise, 1-9, 1-25, 1-27, 1-31
Notebook Computer, 1-9
Null Modem Cable, 1-9

O
Operational Programs, 1-15

P
Payload, 1-37
Payload Capacity, 1-40
PC, 1-10, 1-11, 1-14
Power Block, 1-40
Programs, 1-15
PSB BUS ERROR, 1-11

R
Reduction Unit, 1-37, 1-40

IN-4 December 17, 2002

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INDEX

Repair Personnel, I-3

Repeat Mode, 1-15, 1-46
Robot Data, 1-9, 1-14, 1-15
Robot Data Sheet, 1-9, 1-14
Robot Programs, 1-9

S
S1 Harness, 1-17, 1-19, 1-22, 1-26, 1-33
S2-8, 1-12
S2-S7 Harness, 1-19, 1-22, 1-26, 1-33
Safeguarded Space, I-2, 1-25, 1-32
Safety Circuit, 1-46, 1-48
Safety Device, 1-46
Safety Fence Switch, 1-46
Screen, 1-3, 1-7
Separate Harnesses, 1-44
Separate Signal Harness, 1-17, 1-19
Servo Amplifier, 1-36, 1-40, 1-43, 1-44
Servo Software, 1-7, 1-8, 1-9, 1-12, 1-15
Servo Spot Weld Gun, 1-21, 1-23, 1-27, 1-30, 1-41
Signal Harness, 1-17
Snag, 1-37
Software, 1-9, 1-15, 2-2, 2-3, 2-4
Software Bugs, 1-11
Software Disconnect, 1-23
Software Management, 2-3
Spare Parts, I-2, I-3
Special Tools, I-2, I-3
Speed, 1-37
SVER, 1-42
Switches, 1-26
Symptoms, I-2
System Recovery, 1-15

T
TB2, 1-46
Teach Mode, 1-14, 1-46
Test Points, 1-4, 1-19, 1-46
TIME, 1-14
Time Data, 1-14
Tool Changer, 1-23, 1-30
Tool Kit, I-3
TP, 1-6, 1-7, 1-8, 1-9
TP Software, 1-6, 1-7, 1-8, 1-9
TP1, 1-4, 1-46
TP1G, 1-46
TP3, 1-4
TP4(BAT), 1-19
TP5(GND), 1-19
TPG(GND), 1-19
Trigger Switch, 1-46
Type 2 Teach Pendant, 1-3, 1-7, 1-46

December 17, 2002 IN-5

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INDEX

U
U Series Robot, 1-18
User Program, 1-14

V
Video Board, 1-7, 1-8
Video Signal, 1-7
VME Bus, 1-11
VME BUS ERROR, 1-11

X
X1, 1-6
X2 PC Terminal Port, 1-10
X3, 1-22, 1-26, 1-33
X3A, 1-22, 1-26, 1-33
XFG-CN7, 1-19, 1-22, 1-26, 1-33
XHP-CN1, 1-46

Z
Z Series Robot, 1-18
Zeroing, 1-19

IN-6 December 17, 2002