Kawasaki Robot Controller
E Series
Troubleshooting
Manual
Kawasaki Heavy Industries, Ltd.
90206－1045DEA
E Series Controller
Kawasaki Robot Troubleshooting Manual
PREFACE
This manual is for troubleshooting the E Series Controllers (standard spec.).
This manual describes controller composition and the information necessary for troubleshooting
including: parts layout inside controller, power supply circuit, system diagram, switch settings for
printed board, etc. This information is given assuming the conditions below are met:
• Kawasaki Machine Systems Maintenance course and safety education have been completed
before starting operation.
• Robot and Controller are installed and connected per “Installation and Connection Manual”.
• Controller and peripheral devices are connected per “External I/O Manual”.
• Robot is being operated per “Operation Manual”.
This manual describes troubleshooting procedures in as much detail as possible. However,
because it is not possible to predict every possible trouble that can occur with the robot, only the
most important troubleshooting measures are presented here. Therefore, should any
unexplained questions or problems arise, please contact Kawasaki Machine Systems. Refer to
the contact information listed on the rear cover of this manual for the nearest Kawasaki Machine
Systems office.
Read and understand this manual and other related documents thoroughly, and keep the manual
for future reference to prepare for trouble.
This Manual describes the following controller models.
E20, E22, E24 (Japan Spec.)
E40, E42, E44 (Europe Spec.)
1. This manual does not describe troubleshooting for the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the rights to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2009 Kawasaki Heavy Industries Ltd. All rights reserved.
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E Series Controller
Kawasaki Robot Troubleshooting Manual
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
！
DANGER
Failure to comply with indicated matters can result in
imminent injury or death.
！ WARNING
Failure to comply with indicated matters may possibly lead
to injury or death.
！ CAUTION
Failure to comply with indicated matters may lead to
physical injury and/or mechanical damage.
[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation and maintenance.
！
WARNING
1. The accuracy and effectiveness of the diagrams, procedures, and detail
explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention when
using this manual to perform any work. Should any unexplained
questions or problems arise, please contact Kawasaki Machine Systems.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in safety,
read and fully understand the safety manual, all pertinent laws, regulations
and related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.
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E Series Controller
Kawasaki Robot Troubleshooting Manual
INTRODUCTORY NOTES
1. HARDWARE KEYS AND SWITCHES (BUTTON)
E series controller provides hardware keys and switches on the operation panel and the teach
pendant for various kinds of operations. In this manual the names of the hardware keys and
switches are enclosed with a square as follows. The terms “key” or “switch” which should
follow the relevant names are sometimes omitted for simpler expression. When pressing two or
more keys at the same time, the keys are indicated by “+” as shown in the example below.
EXAMPLES
ENTER: expresses the hardware key “ENTER”.
TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.
A+MENU: indicates pressing and holding down A then pressing MENU.
2. SOFTWARE KEYS AND SWITCHES
E series controller provides software keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this
manual, the names of software keys and switches are enclosed by “< >” parentheses. The terms
“key” or “switch” which should follow the relevant names are sometimes omitted for simpler
expression.
EXAMPLES
<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.
3. SELECTION ITEMS
Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].
EXAMPLES
[Auxiliary Function]: expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the ↵ key. For
detailed description, this procedure should be described every time, but
“select [XXX] item” will be used instead for simpler expression.
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E Series Controller
Kawasaki Robot Troubleshooting Manual
CONTENTS
1.0
1.1
1.1.1
1.1.2
1.2
1.2.1
1.2.1.1
1.2.2
1.2.3
Composition of E Series Controller･･････････････････････････････････････････ 1-1
External View of Controller ････････････････････････････････････････････････ 1-2
Controller Main Body ･････････････････････････････････････････････････････ 1-2
Teach Pendant ････････････････････････････････････････････････････････････ 1-8
Controller Device and Its Arrangement ･･････････････････････････････････････ 1-9
Controller Front ･･･････････････････････････････････････････････････････････ 1-9
Operation Panel ･･････････････････････････････････････････････････････････ 1-11
Inside of Controller･･･････････････････････････････････････････････････････ 1-13
Schematic Diagram･･･････････････････････････････････････････････････････ 1-17
2.0
2.1
2.1.1
2.1.2
2.1.3
2.2
2.2.1
2.2.2
2.2.2.1
2.2.2.2
2.2.2.3
2.2.2.4
2.2.2.5
2.3
2.3.1
2.3.2
2.3.2.1
2.3.2.2
2.3.2.3
2.3.2.4
2.3.2.5
2.3.2.6
2.3.2.7
2.3.3
2.4
Description of Controller･･･････････････････････････････････････････････････ 2-1
Teach Pendant ････････････････････････････････････････････････････････････ 2-4
Functions of Teach Pendant ････････････････････････････････････････････････ 2-4
Overview of Teach Pendant ････････････････････････････････････････････････ 2-4
System Configuration of Teach Pendant ･････････････････････････････････････ 2-5
1TA Board (Main CPU Board)･･････････････････････････････････････････････ 2-6
Main Functions ･･･････････････････････････････････････････････････････････ 2-6
Connectors, LEDs, Check Pins and DIP Switches･････････････････････････････ 2-7
Layout ･･･････････････････････････････････････････････････････････････････ 2-7
Connectors ･･･････････････････････････････････････････････････････････････ 2-8
LEDs ････････････････････････････････････････････････････････････････････ 2-8
Check Pins ･･･････････････････････････････････････････････････････････････ 2-8
DIP Switches ･････････････････････････････････････････････････････････････ 2-9
1TR Board (Power Sequence Board) ･･･････････････････････････････････････ 2-10
Main Functions ･･････････････････････････････････････････････････････････ 2-10
Switches, Connectors, Jumpers, LEDs, Check Pins, and Fuses ････････････････ 2-11
Layout ･･････････････････････････････････････････････････････････････････ 2-11
Switch Function and Settings ･･････････････････････････････････････････････ 2-12
Connectors ･･････････････････････････････････････････････････････････････ 2-12
Jumber Settings ･･････････････････････････････････････････････････････････ 2-12
LEDs ･･･････････････････････････････････････････････････････････････････ 2-13
Check pins ･･････････････････････････････････････････････････････････････ 2-13
Fuse ････････････････････････････････････････････････････････････････････ 2-13
Connection with External Circuits (Safety Circuit, etc.)･･･････････････････････ 2-14
1TX Board (Mother Board) ･･･････････････････････････････････････････････ 2-15
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E Series Controller
Kawasaki Robot Troubleshooting Manual
2.4.1
2.4.1.1
2.4.1.2
2.4.1.3
2.5
2.5.1
2.5.2
2.5.2.1
2.5.2.2
2.5.2.3
2.5.2.4
2.5.2.5
2.5.2.6
2.6
2.6.1
2.6.1.1
2.6.1.2
2.6.1.3
2.6.1.4
2.6.2
2.6.2.1
2.6.2.2
2.6.2.3
2.6.2.4
2.7
2.7.1
2.7.1.1
2.7.1.2
2.7.1.3
2.7.1.4
2.7.1.5
2.7.1.6
2.7.2
2.7.2.1
2.7.2.2
2.7.2.3
2.7.2.4
2.7.2.5
Connectors and Jumpers ･･････････････････････････････････････････････････ 2-15
Layout ･･････････････････････････････････････････････････････････････････ 2-15
Connectors ･･････････････････････････････････････････････････････････････ 2-16
Jumper Settings ･･････････････････････････････････････････････････････････ 2-16
1TW Board (IO Board) (Option) ･･･････････････････････････････････････････ 2-17
Specifications ････････････････････････････････････････････････････････････ 2-17
Connectors, LEDs, Check pins and Switches ････････････････････････････････ 2-18
Layout ･･････････････････････････････････････････････････････････････････ 2-18
Connectors ･･････････････････････････････････････････････････････････････ 2-18
LEDs ･･･････････････････････････････････････････････････････････････････ 2-19
Check pins ･･････････････････････････････････････････････････････････････ 2-19
Switches ････････････････････････････････････････････････････････････････ 2-19
Pin Assignment ･･････････････････････････････････････････････････････････ 2-21
1FG/1HG Board (Battery Backup Board for Encoder)････････････････････････ 2-22
1FG Board ･･････････････････････････････････････････････････････････････ 2-22
Main Functions ･･････････････････････････････････････････････････････････ 2-22
Layout ･･････････････････････････････････････････････････････････････････ 2-22
Check Pins ･･････････････････････････････････････････････････････････････ 2-23
Connectors ･･････････････････････････････････････････････････････････････ 2-23
1HG Board ･･････････････････････････････････････････････････････････････ 2-24
Main Functions ･･････････････････････････････････････････････････････････ 2-24
Layout ･･････････････････････････････････････････････････････････････････ 2-24
Check Pins ･･････････････････････････････････････････････････････････････ 2-24
Connectors ･･････････････････････････････････････････････････････････････ 2-24
1PV/1TK Board (Arm ID Board) (Option) ･･････････････････････････････････ 2-25
1PV board ･･･････････････････････････････････････････････････････････････ 2-25
Layout ･･････････････････････････････････････････････････････････････････ 2-25
1PV Board Connectors････････････････････････････････････････････････････ 2-25
LEDs ･･･････････････････････････････････････････････････････････････････ 2-26
Check Pins ･･････････････････････････････････････････････････････････････ 2-26
Switches ････････････････････････････････････････････････････････････････ 2-26
1JD/1JE Board Connectors ････････････････････････････････････････････････ 2-26
1TK Board ･･････････････････････････････････････････････････････････････ 2-27
Layout ･･････････････････････････････････････････････････････････････････ 2-27
1TK Board Connectors ･･･････････････････････････････････････････････････ 2-27
LEDs ･･･････････････････････････････････････････････････････････････････ 2-27
Check Pins ･･････････････････････････････････････････････････････････････ 2-28
Switches ････････････････････････････････････････････････････････････････ 2-28
v
E Series Controller
Kawasaki Robot Troubleshooting Manual
2.7.2.6
2.8
2.8.1
2.9
2.9.1
2.9.1.1
2.9.1.2
2.9.1.2.1
2.9.1.2.2
2.9.1.2.3
2.9.1.2.4
2.9.1.2.5
2.9.1.2.6
2.9.1.3
2.9.2
2.9.2.1
2.9.2.2
2.9.2.2.1
2.9.2.2.2
2.9.2.2.3
2.10
2.10.1
2.10.2
2.10.3
2.11
2.11.1
2.11.2
2.11.3
2.11.3.1
2.11.3.2
2.11.3.3
2.12
2.12.1
2.12.1.1
2.12.1.2
2.12.1.2.1
2.12.1.2.2
2.12.1.2.3
1TY Board Connectors ･･･････････････････････････････････････････････････ 2-28
Encoder ･････････････････････････････････････････････････････････････････ 2-29
Main Functions ･･････････････････････････････････････････････････････････ 2-29
Servo Amplifier Unit for 6 Axes ･･･････････････････････････････････････････ 2-31
1TB Board (Servo Board) ･････････････････････････････････････････････････ 2-31
Main Functions ･･････････････････････････････････････････････････････････ 2-31
Connectors, Jumpers, LEDs, Check Pins, Switches ･･････････････････････････ 2-32
Layout ･･････････････････････････････････････････････････････････････････ 2-32
Connectors ･･････････････････････････････････････････････････････････････ 2-33
Jumpers ･････････････････････････････････････････････････････････････････ 2-34
LEDs ･･･････････････････････････････････････････････････････････････････ 2-34
Check Pins ･･････････････････････････････････････････････････････････････ 2-35
Switches ････････････････････････････････････････････････････････････････ 2-36
1TB Board Software･･････････････････････････････････････････････････････ 2-36
1TC/1TD Board (Power Block Board)･･････････････････････････････････････ 2-37
Main Functions ･･････････････････････････････････････････････････････････ 2-37
Conectors, Check Pins ････････････････････････････････････････････････････ 2-38
Layout ･･････････････････････････････････････････････････････････････････ 2-38
Connectors (For 1TC/1TD)････････････････････････････････････････････････ 2-39
Check Pins (For 1TC/1TD)････････････････････････････････････････････････ 2-39
Amplifier Unit for Single Axis ･････････････････････････････････････････････ 2-40
Specifications ････････････････････････････････････････････････････････････ 2-40
Main Functions ･･････････････････････････････････････････････････････････ 2-40
Connectors ･･････････････････････････････････････････････････････････････ 2-40
DC Power Supply for Control (AVR)･･･････････････････････････････････････ 2-41
Specifications ････････････････････････････････････････････････････････････ 2-41
Main Functions ･･････････････････････････････････････････････････････････ 2-41
Connectors and Output Voltage Adjustment ･････････････････････････････････ 2-42
Layout ･･････････････････････････････････････････････････････････････････ 2-42
Connectors ･･････････････････････････････････････････････････････････････ 2-42
Output Voltage Adjusting Knob ････････････････････････････････････････････ 2-42
MC Unit ････････････････････････････････････････････････････････････････ 2-43
1TU Board (MC Power Board) ････････････････････････････････････････････ 2-43
Main Function ･･･････････････････････････････････････････････････････････ 2-43
Connectors, LEDs, Check Pins ････････････････････････････････････････････ 2-44
Layout ･･････････････････････････････････････････････････････････････････ 2-44
Connectors ･･････････････････････････････････････････････････････････････ 2-44
LEDs ･･･････････････････････････････････････････････････････････････････ 2-45
vi
E Series Controller
Kawasaki Robot Troubleshooting Manual
2.12.1.2.4
2.12.2
2.12.2.1
2.12.2.2
2.12.2.2.1
2.12.2.2.2
2.12.2.2.3
2.12.2.2.4
2.12.2.2.5
2.12.2.2.6
2.13
Check Pins ･･････････････････････････････････････････････････････････････ 2-45
1TQ/1TV Boards (MC Control Board) ･････････････････････････････････････ 2-46
Main Functions ･･････････････････････････････････････････････････････････ 2-46
Connectors, Jumpers, LEDs, Check Pins, Switch ････････････････････････････ 2-47
Layout ･･････････････････････････････････････････････････････････････････ 2-47
Connectors ･･････････････････････････････････････････････････････････････ 2-48
Jumper Settings ･･････････････････････････････････････････････････････････ 2-49
LEDs ･･･････････････････････････････････････････････････････････････････ 2-49
Check Pins ･･････････････････････････････････････････････････････････････ 2-50
Switch ･･････････････････････････････････････････････････････････････････ 2-51
Manual Brake Release Switch (option) ･････････････････････････････････････ 2-52
3.0
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Troubleshooting･･･････････････････････････････････････････････････････････ 3-1
Initial Troubles and Countermeasures････････････････････････････････････････ 3-2
Initial Trouble 1: Controller power Does Not Turn ON ････････････････････････ 3-2
Initial Trouble 2: Teach Pendant Is Not Operable･･････････････････････････････ 3-5
Initial Trouble 3: Motor Power Does Not Turn ON････････････････････････････ 3-7
Initial Trouble 4: Robot Does Not Move ･････････････････････････････････････ 3-8
Steady-State Troubles and Countermeasures･･････････････････････････････････ 3-9
Error Classification ････････････････････････････････････････････････････････ 3-9
Error Handling by Robot ･･････････････････････････････････････････････････ 3-10
Further Error Classification and Error Numbers･･････････････････････････････ 3-11
Error Display ････････････････････････････････････････････････････････････ 3-12
Error List････････････････････････････････････････････････････････････････ 3-12
Common Error Examples ･････････････････････････････････････････････････ 3-13
4.0
4.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.3
4.3.1
4.3.2
4.3.3
4.4
Procedures for Replacement ････････････････････････････････････････････････ 4-1
General Safety Precautions on Replacement･･････････････････････････････････ 4-2
Parts in Card Rack･････････････････････････････････････････････････････････ 4-5
1TA Board (Main CPU Board)･･････････････････････････････････････････････ 4-5
CF card on 1TA Board (Main CPU Board) ･･･････････････････････････････････ 4-6
1TR Board (Power Sequence Board) ････････････････････････････････････････ 4-8
AVR ･････････････････････････････････････････････････････････････････････ 4-8
Servo Amplifier Unit for 6 Axes Part ･･･････････････････････････････････････ 4-10
Servo Amplifier Unit for 6 Axes ･･･････････････････････････････････････････ 4-10
1TB Board (Servo Board) ･････････････････････････････････････････････････ 4-12
Amplifier Unit for Single Axis ･････････････････････････････････････････････ 4-14
MC Unit Part ････････････････････････････････････････････････････････････ 4-15
vii
E Series Controller
Kawasaki Robot Troubleshooting Manual
4.4.1
4.4.2
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.6
4.6.1
4.6.2
4.7
4.7.1
MC Unit ････････････････････････････････････････････････････････････････ 4-15
1TQ/1TV Boards (MC Control Board) ･････････････････････････････････････ 4-16
Fans ････････････････････････････････････････････････････････････････････ 4-18
Fans for Card Rack ･･･････････････････････････････････････････････････････ 4-18
Fans for Servo Amp. Unit for 6 Axes ･･･････････････････････････････････････ 4-18
Fan for Amp. Unit for Single Axis･･････････････････････････････････････････ 4-19
Fan inside MC Unit･･･････････････････････････････････････････････････････ 4-19
Batteries･････････････････････････････････････････････････････････････････ 4-21
Coin Battery on 1TA Board････････････････････････････････････････････････ 4-21
Battery on 1FG/1HG Board ･･･････････････････････････････････････････････ 4-22
Fuses ･･･････････････････････････････････････････････････････････････････ 4-23
Fuses on 1TR Board ･･････････････････････････････････････････････････････ 4-23
5.0
5.1
5.1.1
5.1.2
5.1.3
5.2
5.2.1
5.2.2
5.2.3
5.2.4
Schematic Diagrams of Separate and Machine Harnesses ･･････････････････････ 5-1
Separate Harness ･･････････････････････････････････････････････････････････ 5-2
E20/E40 Separate Harness Wire Distribution List ･････････････････････････････ 5-2
E22/E42 Separate Harness Wire Distribution List ･････････････････････････････ 5-4
E24/E44 Separate Harness Wire Distribution List ･････････････････････････････ 5-6
Machine Harness･･････････････････････････････････････････････････････････ 5-8
R Series ･･････････････････････････････････････････････････････････････････ 5-8
ZX, ZT Series････････････････････････････････････････････････････････････ 5-11
MX Series ･･･････････････････････････････････････････････････････････････ 5-15
MD Series ･･･････････････････････････････････････････････････････････････ 5-19
Appendix Error Message List ････････････････････････････････････････････････････････A-1
viii
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
1.0 COMPOSITION OF E SERIES CONTROLLER
The E Series Controller is composed of a controller body and a teach pendant.
1.1
1.1.1
1.1.2
1.2
1.2.1
1.2.1.1
1.2.2
1.2.3
External View of Controller ････････････････････････････････････････････ 1-2
Controller Main Body･････････････････････････････････････････････････ 1-2
Teach Pendant･･･････････････････････････････････････････････････････ 1-8
Controller Device and Its Arrangement ･･･････････････････････････････････ 1-9
Controller Front ･････････････････････････････････････････････････････ 1-9
Operation Panel ････････････････････････････････････････････････････ 1-11
Inside of Controller･･････････････････････････････････････････････････ 1-13
Schematic Diagram･･････････････････････････････････････････････････ 1-17
1-1
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
1.1 EXTERNAL VIEW OF CONTROLLER
The figures below show the exterior of the controller and the teach pendant.
1.1.1 CONTROLLER MAIN BODY
The E Series Controller is shown below.
450
Left view
Front view
Right view
Rear view
950
550
E20 Controller
1-2
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
450
950
550
Left view
Front view
Right view
Rear view
E22 Controller
1-3
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
450
950
550
Left view
Front view
Right view
Rear view
E24 Controller
1-4
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
550
1200
550
Left view
Front view
Right view
Rear view
E40 Controller
1-5
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
550
1200
550
Left view
Front view
Right view
Rear view
E42 Controller
1-6
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
550
1200
550
Left view
Front view
Right view
Rear view
E44 Controller
1-7
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
1.1.2 TEACH PENDANT
The teach pendant is mainly composed of the following parts.
1. LCD (Liquid crystal display) with touch panel
2. Hardware operation keys
3. Emergency Stop switch
4. Teach lock switch
5. Deadman switches (Two on the back)
LCD with Touch Panel
Emergency Stop Switch
Teach Lock Switch
Hardware Operation Keys
(In the dashed line)
Front view
Deadman Switches
(3 position)
Rear view
1-8
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
1.2 CONTROLLER DEVICE AND ITS ARRANGEMENT
In the E Series Controller, operation switches and connectors are provided on the outer surface of
the controller, and control devices are located inside the controller.
1.2.1 CONTROLLER FRONT
The following parts are arranged on the front part of the controller.
E2x/E4x controller
1. Operation panel
2. Hook (for hanging Teach pendant / Cable)
3. Teach pendant connector: Connects teach pendant cables.
4. Teach pendant (TP)
5. Accessory panel: USB port, RS-232C port, 100 V AC outlet (Option for Japan spec.) are
provided under the cover of the accessory panel. Press the cover to open.
(See figure on next page.)
6. Controller power switch: Turns ON/OFF the controller power. At power ON, controller door
cannot be opened.
7. Coin lock
5. Accessory panel
1. Operation panel
2. Hook (for hanging Teach
pendant / Cable)
6. Controller power switch
3. Teach pendant connector:
Connects teach pendant cables.
7. Coin lock
4. Teach pendant
Controller front
1-9
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
USB port
RS-232C port
Internal layout of Accessory Panel
Connector for separate harness
Rear side (e.g.: E20 controller)
1-10
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
1.2.1.1 OPERATION PANEL
The following buttons, switches, and display lamps are built into the operation panel to perform
the functions below.
Standard operation panel for E2x controller
1. Switches
(1) TEACH/REPEAT switch
: Selects TEACH/REPEAT mode.
(2) EMERGENCY STOP switch : Emergency stop
2. Lamp
CONTROLLER POWER lamp
Teach/Repeat switch
Controller power lamp
Emergency stop switch
Standard operation panel for E4x controller (Option for E2x)
1. Switches
(1) FAST CHECK/TEACH/REPEAT switch : Selects FAST CHECK/TEACH/REPEAT
mode.
(2) EMERGENCY STOP switch : Emergency stop
2. Lamp
CONTROLLER POWER lamp
Fast Check/
Teach/Repeat switch
Controller power lamp
1-11
Emergency stop switch
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
Optional operation panel
1. Buttons/Switches
(1) MOTOR POWER button
: Motor power ON
(2) CYCLE START button
: Cycle start
(3) ERROR RESET button
: Error reset
(4) HOLD/RUN switch
: Switches RUN/HOLD.
2. Lamps
MOTOR POWER lamp, CYCLE START lamp, ERROR lamp
Hold/Run switch
Cycle start
button/lamp
Motor power
button/lamp
1-12
Error reset button
Error lamp
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
1.2.2 INSIDE OF CONTROLLER
Inside of the E2x/E4x Controller houses main three units: Card rack unit, MC unit, and Servo
amplifier unit.
1. Card rack unit
Printed boards and DC power supply (AVR) are housed in this rack. Main CPU board, power
sequence board, and mother board are the standard boards common to all controller models, and
four optional IO boards can also be housed.
(1) Mother board (1TX board)
(2) Main CPU board (1TA board)
(3) Power sequence board (1TR board)
(4) DC power supply for control (AVR)
(5) IO board (1TW board)
2. MC unit
(1) Magnetic contactors
(2) Fan
(3) MC control board (1TQ/1TV board)
(4) MC power board (1TU board)
(5) Power supply for power module
The whole MC unit can be replaced after disconnecting the connectors. (Refer to 4.0 Procedures
for Replacement for more details.)
3. Servo amplifier unit
Each servo amplifier unit of E controller is composed of the following parts:
(1) Power block + Case (Six 1TC and 1TD boards included.)*
(2) Servo board (1TA board)
(3) Plastic cover
NOTE* How to combine the 1TC and 1TD boards depends on the motor capacity used for the
robot arm.
If any replacements are needed, the replacement of whole (1) or (2) is necessary. (Refer to 4.0
Procedures for Replacement for more details.)
1-13
E Series Controller
Kawasaki Robot Troubleshooting Manual
！
1. Composition of E Series Controller
WARNING
1. The MC unit and servo amplifier unit have their own power
chargers (P-N voltage). Prior to performing any work on the
units, turn OFF the controller power and wait at least 3 min.
2. When replacing servo amplifier unit, check over the part number
to avoid mistake in replacement.
3. When connecting cables, make sure that all the cable markings
correspond with markings of the terminal block and the
connector numbers.
1-14
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
E20/E22/E24 Layout of Internal Parts
DC power supply for
control (AVR)
Card rack unit
Controller power
switch
IO board
(1TW board)*
Power sequence board
(1TR board)
Amplifier unit
for single axis*
Main CPU board
(1TA board)
Brake release switch*
Servo amplifier unit
for 6 axes
MC unit
Servo board (1TB board)
(Mounted under the cover.）
* : Option
1-15
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
E40/E42/E44 Layout of Internal Parts
DC power supply for
control (AVR)
Card rack unit
Controller power
switch
IO board
(1TW board)*
Power sequence board
(1TR board)
Amplifier unit
for single axis*
Main CPU board
(1TA board)
Brake release switch*
MC unit
Servo amplifier unit
for 6 axes
Servo board (1TB board)
(Mounted under the cover.）
* : Option
1-16
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
1.2.3 SCHEMATIC DIAGRAM
1. E20 controller
1-17
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
2. E22 controller
1-18
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
3. E24 controller
1-19
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
4. E40 controller
1-20
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
5. E42 controller
1-21
E Series Controller
Kawasaki Robot Troubleshooting Manual
1. Composition of E Series Controller
6. E44 controller
1-22
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.0 DESCRIPTION OF CONTROLLER
This chapter describes in detail each of the printed boards and units that make up the E Series
Controller.
2.1
2.1.1
2.1.2
2.1.3
2.2
2.2.1
2.2.2
2.2.2.1
2.2.2.2
2.2.2.3
2.2.2.4
2.2.2.5
2.3
2.3.1
2.3.2
2.3.2.1
2.3.2.2
2.3.2.3
2.3.2.4
2.3.2.5
2.3.2.6
2.3.2.7
2.3.3
2.4
2.4.1
2.4.1.1
2.4.1.2
2.4.1.3
2.5
2.5.1
2.5.2
2.5.2.1
2.5.2.2
2.5.2.3
Teach Pendant ･････････････････････････････････････････････････････ 2-4
Functions of Teach Pendant･･･････････････････････････････････････････ 2-4
Overview of Teach Pendant･･･････････････････････････････････････････ 2-4
System Configuration of Teach Pendant ･････････････････････････････････ 2-5
1TA Board (Main CPU Board) ････････････････････････････････････････ 2-6
Main Functions ････････････････････････････････････････････････････ 2-6
Connectors, LEDs, Check Pins and DIP Switches ･････････････････････････ 2-7
Layout ･･･････････････････････････････････････････････････････････ 2-7
Connectors････････････････････････････････････････････････････････ 2-8
LEDs ････････････････････････････････････････････････････････････ 2-8
Check Pins ････････････････････････････････････････････････････････ 2-8
DIP Switches ･･････････････････････････････････････････････････････ 2-9
1TR Board (Power Sequence Board) ･･････････････････････････････････ 2-10
Main Functions ･･･････････････････････････････････････････････････ 2-10
Switches, Connectors, Jumpers, LEDs, Check Pins, and Fuses ･･････････････ 2-11
Layout ･･････････････････････････････････････････････････････････ 2-11
Switch Function and Settings ････････････････････････････････････････ 2-12
Connectors･･･････････････････････････････････････････････････････ 2-12
Jumber Settings ･･･････････････････････････････････････････････････ 2-12
LEDs ･･･････････････････････････････････････････････････････････ 2-13
Check pins ･･･････････････････････････････････････････････････････ 2-13
Fuse ････････････････････････････････････････････････････････････ 2-13
Connection with External Circuits (Safety Circuit, etc.) ････････････････････ 2-14
1TX Board (Mother Board)･･････････････････････････････････････････ 2-15
Connectors and Jumpers ････････････････････････････････････････････ 2-15
Layout ･･････････････････････････････････････････････････････････ 2-15
Connectors･･･････････････････････････････････････････････････････ 2-16
Jumper Settings ･･･････････････････････････････････････････････････ 2-16
1TW Board (IO Board) (Option)･･････････････････････････････････････ 2-17
Specifications･････････････････････････････････････････････････････ 2-17
Connectors, LEDs, Check pins and Switches ････････････････････････････ 2-18
Layout ･･････････････････････････････････････････････････････････ 2-18
Connectors･･･････････････････････････････････････････････････････ 2-18
LEDs ･･･････････････････････････････････････････････････････････ 2-19
2-1
E Series Controller
Kawasaki Robot Troubleshooting Manual
2.5.2.4
2.5.2.5
2.5.2.6
2.6
2.6.1
2.6.1.1
2.6.1.2
2.6.1.3
2.6.1.4
2.6.2
2.6.2.1
2.6.2.2
2.6.2.3
2.6.2.4
2.7
2.7.1
2.7.1.1
2.7.1.2
2.7.1.3
2.7.1.4
2.7.1.5
2.7.1.6
2.7.2
2.7.2.1
2.7.2.2
2.7.2.3
2.7.2.4
2.7.2.5
2.7.2.6
2.8
2.8.1
2.9
2.9.1
2.9.1.1
2.9.1.2
2.9.1.2.1
2.9.1.2.2
2.9.1.2.3
2.9.1.2.4
2. Description of Controller
Check pins ･･･････････････････････････････････････････････････････ 2-19
Switches･････････････････････････････････････････････････････････ 2-19
Pin Assignment ･･･････････････････････････････････････････････････ 2-21
1FG/1HG Board (Battery Backup Board for Encoder) ･････････････････････ 2-22
1FG Board ･･･････････････････････････････････････････････････････ 2-22
Main Functions ･･･････････････････････････････････････････････････ 2-22
Layout ･･････････････････････････････････････････････････････････ 2-22
Check Pins ･･･････････････････････････････････････････････････････ 2-23
Connectors･･･････････････････････････････････････････････････････ 2-23
1HG Board･･･････････････････････････････････････････････････････ 2-24
Main Functions ･･･････････････････････････････････････････････････ 2-24
Layout ･･････････････････････････････････････････････････････････ 2-24
Check Pins ･･･････････････････････････････････････････････････････ 2-24
Connectors･･･････････････････････････････････････････････････････ 2-24
1PV/1TK Board (Arm ID Board) (Option) ･･････････････････････････････ 2-25
1PV board ･･･････････････････････････････････････････････････････ 2-25
Layout ･･････････････････････････････････････････････････････････ 2-25
1PV Board Connectors ･････････････････････････････････････････････ 2-25
LEDs ･･･････････････････････････････････････････････････････････ 2-26
Check Pins ･･･････････････････････････････････････････････････････ 2-26
Switches･････････････････････････････････････････････････････････ 2-26
1JD/1JE Board Connectors ･･････････････････････････････････････････ 2-26
1TK Board ･･･････････････････････････････････････････････････････ 2-27
Layout ･･････････････････････････････････････････････････････････ 2-27
1TK Board Connectors ･････････････････････････････････････････････ 2-27
LEDs ･･･････････････････････････････････････････････････････････ 2-27
Check Pins ･･･････････････････････････････････････････････････････ 2-28
Switches･････････････････････････････････････････････････････････ 2-28
1TY Board Connectors ･････････････････････････････････････････････ 2-28
Encoder ･････････････････････････････････････････････････････････ 2-29
Main Functions ･･･････････････････････････････････････････････････ 2-29
Servo Amplifier Unit for 6 Axes ･･････････････････････････････････････ 2-31
1TB Board (Servo Board) ･･･････････････････････････････････････････ 2-31
Main Functions ･･･････････････････････････････････････････････････ 2-31
Connectors, Jumpers, LEDs, Check Pins, Switches ･･･････････････････････ 2-32
Layout ･･････････････････････････････････････････････････････････ 2-32
Connectors･･･････････････････････････････････････････････････････ 2-33
Jumpers ･････････････････････････････････････････････････････････ 2-34
LEDs ･･･････････････････････････････････････････････････････････ 2-34
2-2
E Series Controller
Kawasaki Robot Troubleshooting Manual
2.9.1.2.5
2.9.1.2.6
2.9.1.3
2.9.2
2.9.2.1
2.9.2.2
2.9.2.2.1
2.9.2.2.2
2.9.2.2.3
2.10
2.10.1
2.10.2
2.10.3
2.11
2.11.1
2.11.2
2.11.3
2.11.3.1
2.11.3.2
2.11.3.3
2.12
2.12.1
2.12.1.1
2.12.1.2
2.12.1.2.1
2.12.1.2.2
2.12.1.2.3
2.12.1.2.4
2.12.2
2.12.2.1
2.12.2.2
2.12.2.2.1
2.12.2.2.2
2.12.2.2.3
2.12.2.2.4
2.12.2.2.5
2.12.2.2.6
2.13
2. Description of Controller
Check Pins ･･･････････････････････････････････････････････････････ 2-35
Switches･････････････････････････････････････････････････････････ 2-36
1TB Board Software ･･･････････････････････････････････････････････ 2-36
1TC/1TD Board (Power Block Board) ･････････････････････････････････ 2-37
Main Functions ･･･････････････････････････････････････････････････ 2-37
Conectors, Check Pins ･･････････････････････････････････････････････ 2-38
Layout ･･････････････････････････････････････････････････････････ 2-38
Connectors (For 1TC/1TD) ･･････････････････････････････････････････ 2-39
Check Pins (For 1TC/1TD) ･･････････････････････････････････････････ 2-39
Amplifier Unit for Single Axis ･･･････････････････････････････････････ 2-40
Specifications･････････････････････････････････････････････････････ 2-40
Main Functions ･･･････････････････････････････････････････････････ 2-40
Connectors･･･････････････････････････････････････････････････････ 2-40
DC Power Supply for Control (AVR) ･･････････････････････････････････ 2-41
Specifications･････････････････････････････････････････････････････ 2-41
Main Functions ･･･････････････････････････････････････････････････ 2-41
Connectors and Output Voltage Adjustment ･････････････････････････････ 2-42
Layout ･･････････････････････････････････････････････････････････ 2-42
Connectors･･･････････････････････････････････････････････････････ 2-42
Output Voltage Adjusting Knob ･･････････････････････････････････････ 2-42
MC Unit･････････････････････････････････････････････････････････ 2-43
1TU Board (MC Power Board) ･･･････････････････････････････････････ 2-43
Main Function ････････････････････････････････････････････････････ 2-43
Connectors, LEDs, Check Pins ･･･････････････････････････････････････ 2-44
Layout ･･････････････････････････････････････････････････････････ 2-44
Connectors･･･････････････････････････････････････････････････････ 2-44
LEDs ･･･････････････････････････････････････････････････････････ 2-45
Check Pins ･･･････････････････････････････････････････････････････ 2-45
1TQ/1TV Boards (MC Control Board) ･････････････････････････････････ 2-46
Main Functions ･･･････････････････････････････････････････････････ 2-46
Connectors, Jumpers, LEDs, Check Pins, Switch ･････････････････････････ 2-47
Layout ･･････････････････････････････････････････････････････････ 2-47
Connectors･･･････････････････････････････････････････････････････ 2-48
Jumper Settings ･･･････････････････････････････････････････････････ 2-49
LEDs ･･･････････････････････････････････････････････････････････ 2-49
Check Pins ･･･････････････････････････････････････････････････････ 2-50
Switch ･･････････････････････････････････････････････････････････ 2-51
Manual Brake Release Switch (option) ･････････････････････････････････ 2-52
2-3
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.1 TEACH PENDANT
The teach pendant can be used by connecting the teach pendant cable to the X1 connector on the
front of the controller.
2.1.1 FUNCTIONS OF TEACH PENDANT
1. Display of various kinds of information and conditions by the color LCD
2. Input function by the touch panel on the color LCD
3. Input function by the hardware keys
4. Function of emergency stop, teach lock, and deadman by various dedicated switches
2.1.2 OVERVIEW OF TEACH PENDANT
LCD with
Touch Panel
Emergency Stop
Switch
Teach Lock Switch
Hardware Operation
Keys
(in the dashed line)
Deadman Switches
(3 positions)
Front
Back
2-4
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.1.3 SYSTEM CONFIGURATION OF TEACH PENDANT
The following block diagram shows a configuration of the teach pendant.
Power
sequence
board
Deadman signal
Emergency stop
Teach
pendant
Main CPU
board
RS-422
Image signal (digital RGB)
！
CAUTION
意
1. Prior to using the touch panel, attach the protection sheet. (Three sheets are
included with shipment.) Use only the dedicated touch pen or a PDA touch
pen. Do not operate the touch panel with sharp tools, such as a screw driver,
etc. Doing so may damage the panel.
2. Protect the teach pendant and its LCD from strong impact (Do not drop, etc.).
3. Teach pendant is not explosion proof type. Do not use it in an explosive
environment or work cell.
4. Teach pendant is not waterproof and should be kept out of water, oil, etc.
5. Do not pull the teach pendant cable forcibly or push it into the gap between the
safety fence rails, etc.
2-5
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.2 1TA BOARD (MAIN CPU BOARD)
This board is the main CPU board of the E Series Controller.
The 1TA board executes AS language commands/instructions, processes basic robot motion
planning and communication with internal/external I/O equipment and devices, and conducts
interface controls with these devices.
2.2.1 MAIN FUNCTIONS
The 1TA board performs the following functions:
1.
2.
3.
4.
5.
Stores AS group software and servo group software (in the CF card).
Controls AS software system.
Stores user programs and data in the CF card.
Performs servo data communication with servo board.
Performs digital RGB parallel communication and serial communication via RS-422 with
teach pendant.
6. Functions as an optional slot bus interface. (Communicates with the IO and other optional
boards.)
7. Houses two RS-232C ports. (One is connected to that in accessory panel.)
8. Houses two USB ports. (One is connected to that in accessory panel.)
9. Houses two Ethernet ports.
10. Functions as a clock. (Backed up by a coin battery.)
2-6
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.2.2 CONNECTORS, LEDS, CHECK PINS AND DIP SWITCHES
2.2.2.1 LAYOUT
CN2
CN8
CN13
CN11
CN6 CN7
DIP SW
1 2 34 5 6 78
CN3
Check pins, LEDs
CN4
CN10
Outline view of 1TA board
LD1
TP3
TP4
TP6
TP5
2-7
LD2
LD3
LD4
TP8
TP7
LD5
TP10
TP9
LD7
TP12
TP11
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.2.2.2 CONNECTORS
No.
Contents
CN2
CN3
CN4
CN6
CN7
CN8
CN10
CN11
CN13
Destination
Communication with servo board and TP
RS-232C
RS-232C
USB
USB
System bus
Ethernet
For compact flash
Connector for additional board
Mother board S2
Accessory panel
Accessory panel
Mother board S3
CF card
Additional servo communication board
2.2.2.3 LEDS
No.
Contents
Color
Lighting Condition
LD1
(SYSRUN)
System RUN
Blink at normal state,
Green ON at abnormal state
LD2
(ERROR)
System error
Red
LD3
(PWR)
Power supply
ON at controller power ON,
Green OFF at controller power OFF
LD4
For CF card
(PR.CF_ACT) (Primary)
LD7
(PROC)
CPU overheat
2.2.2.4 CHECK PINS
No.
Function
TP3
+1.8 V power voltage
TP4
+1.05 V power voltage
TP5
GND
TP6
+1.25 V power voltage
TP7
CPU CORE
TP8
+1.35 V power voltage
TP9
+5 V power voltage
TP10
+2.5 V power voltage
TP11
+3.3 V power voltage
TP12
+1.5 V power voltage
OFF at normal state,
ON at abnormal state
ON when CF card inserted,
Green OFF when no CF card inserted,
Blink when accessing the CF
OFF at normal state,
Red
Blink at CPU overheating
Normal range
+1.71 - +1.89 V
+1.00 - +1.10 V
+1.19 - +1.31 V
+1.29 - +1.42 V
+1.29 - +1.41 V
+5.05 - +5.15 V
+2.38 - +2.62 V
+3.25 - +3.35 V
+1.43 - +1.57 V
2-8
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.2.2.5 DIP SWITCHES
DIPSW
No.
1
2
3
4
5
6
7
8
Default (Factory settings)
Function
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Reset*
Used for the system
(Not to be used)
Confirmation query for
initialization at ON
OFF
NOTE*
Use this switch when the controller does not restart even after power is re-supplied at occurrence
of overheating, etc. The restart procedure is shown below:
1. Turn OFF the controller power.
2. Turn ON the DIP switch 1.
3. Turn ON the controller power.
4. Turn OFF the DIP switch 1 in approx. two seconds.
！
CAUTION
Leaving DIP switch 1 ON after procedure 3 makes the
switch OFF forcibly and stop moving. When this state
occurs, execute 1 to 3 again.
2-9
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.3 1TR BOARD (POWER SEQUENCE BOARD)
This is the power sequence board of the E Series Controller. 1TR board monitors conditions of
the power circuits and safety circuits of the E Series Controller, communicates with the 1TA
board (main CPU board), and controls the safety circuits.
2.3.1 MAIN FUNCTIONS
The 1TR board performs the following functions:
1.
2.
3.
4.
Connects the external safety circuits. (Refer to External I/O Manual for more details.)
Detects condition of the safety circuits.
Checks if the safety circuits are normal, and notifies the 1TA board of the result.
Notifies the 1TA board of primary power failure in AVR, and monitors DC power supply
that AVR generates.
5. Cuts OFF output of AVR when abnormality is detected in the primary and DC power
supply.
6. Sets the number of safety circuits (double circuit as standard). To change the setting,
jumper settings on the MC unit is also necessary.*
7. Sets the delay time before cutting OFF the motor power (backup time by hardware) after
switching HOLD/RUN optional switch from RUN to HOLD.
8. Detects fuse blowouts for the safety circuit (F1).
9. Monitors temperature inside the controller and detects error when the temperature becomes
high.
10. Notifies the 1TA of the switch input state of the optional operation panel. Also, lights ON
the lamps on optional operation panel.
11. Enables mounting up to two optional daughter boards.
12. Houses the LS override switch.
NOTE* Changing the number of safety circuits is enabled only for the E2x controllers. In other
controllers, the number of the circuit is set to two and cannot be changed.
2-10
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.3.2 SWITCHES, CONNECTORS, JUMPERS, LEDS, CHECK PINS, AND FUSES
2.3.2.1 LAYOUT
FUSE F1
X9
X8
TP6 TP5
JP1
A1
TP3 TP2
X7
TP4
TP1
SW1
B1
CN1
JP1
A6
SW2
B6
JP2
JP2
A1
B1
ON
1
B6
A6
P2
P1
Outline view of 1TR board (front)
CN10
LD1 LD2 LD3 LD4 LD5
LD6 LD7 LD8 LD10
LD9
CN3
CN4
CN2
Outline view of 1TR board (rear)
2-11
2
3
4
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.3.2.2 SWITCH FUNCTION AND SETTINGS
1. SW1 (LS Override Switch)
The LS Override Switch, yellow press-button switch, is located on the upper front side of the
1TR board. The LS is not effective while pressing the switch.
2. SW2
No.
Function
SW2-1 Sets the number of the safety circuits.
(ON: Single circuit, OFF: Double
circuit)
SW2-2 Sets backup time for HOLD
(ON: 2 seconds, OFF: No setting)
SW2-3 Unused
SW2-4 Unused
Default
OFF: Double circuit
ON: 2 seconds
OFF (modification prohibited)
OFF (modification prohibited)
2.3.2.3 CONNECTORS
No.
X7
X8
X9
P1
P2
CN2
CN3, CN4
CN10
Contents
External emergency stop input
Safety fence, External trigger input, Teaching state
output
External control power ON, External motor ON,
External HOLD input, I/O24 V output
Destination
External wiring
External wiring
System bus
Emergency stop, Safety circuit input/output for
Teach/Repeat, etc.
Option – Connector for 12 V power supply
Connector for optional board
Emergency stop output for Mitsubishi SSC-NET
Mother board S4
Mother board S9
External wiring
－
－
1LP board CN4
2.3.2.4 JUMBER SETTINGS
No.
Contents
CN1
For debug
JP1, JP2
Switches emergency stop monitor.
Jumper JP1: Monitors operation panel/emergency
stop in teach pendant.
Jumper JP2: Not monitor operation panel/emergency
stop in teach pendant.
2-12
Settings
Unconnected.
(modification prohibited)
Jumper JP1
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.3.2.5 LEDS
No.
LD1 (OPEMG)
LD3 (EXEMG)
Contents
EMERGENCY STOP is ON in
operation panel.
EMERGENCY STOP is ON in teach
pendant.
External EMERGENCY STOP is ON.
LD4 (PSERR)
Power sequence error is occurring.
LD5 (WDERR)
Bus access watch dog error is occurring.
LD6 (+3.3V)
Supplying +3.3 V power.
LD7 (+5V)
Supplying +5 V power.
LD8 (+12V)
Supplying +12 V power.
LD9 (+24V)
Supplying +24 V power.
LD10
(ACCESS)
Accessing system bus.
LD2 (TPMEG)
Color
Lighting state
Red OFF at normal state,
ON at emergency stop
Red OFF at normal state,
ON at emergency stop
Red OFF at normal state,
ON at emergency stop
Red
OFF at normal state,
ON at abnormal state
Red OFF at normal state,
ON at abnormal state
Green ON when supplying the
power normally
Green ON when supplying the
power normally
Green ON when supplying the
power normally
Green ON when supplying the
power normally
Green ON at normal state
2.3.2.6 CHECK PINS
No.
Contents
+5 V power supply
+3.3 V power supply
TP1
TP2
TP3
TP4
TP5
TP6
+12 Ｖ power supply
GND
+24 V power supply
24 V GND
Normal range
+5.05 - +5.15 V
+3.25 - +3.35 V
+12.25 - +12.75 V
+23.9 - +24.7 V
-
2.3.2.7 FUSE
No.
F1
Contents
Fuse for emergency stop line (1A)
2-13
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.3.3 CONNECTION WITH EXTERNAL CIRCUITS (SAFETY CIRCUIT, ETC.)
External circuits are connected via the terminal block connector on the front of the 1TR board.
Note that the connection method differs depending on either single or double circuit in the safety
circuit. In the case of double circuit, two input contacts, each one per circuit, needs to be
activated simultaneously. Three connectors X7, X8 and X9 are used for terminal blocks.
Refer to External I/O Manual for more details.
2-14
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.4 1TX BOARD (MOTHER BOARD)
This is the mother board of the E Series Controller. The 1TA board (main CPU board), the 1TR
board (power sequence board), the 1TW board (IO board), other optional boards and the AVR
unit are all connected to the 1TX board.
2.4.1 CONNECTORS AND JUMPERS
2.4.1.1 LAYOUT
S4
S2
S5
S1
S6
S8
J1
1
2
3
S3
S9
X207
S7
X214 X213
X212
X206 X205
J2
X204
Outline view of 1TX board
2-15
1
2
3
X203
J1
J2
X202 X211 X210
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.4.1.2 CONNECTORS
No.
S1
S2
S3
S4
S5
S6
S7
S8
S9
X202
X203
X204
X205
X206
X207
X210
X211
X212
X213
X214
Contents and destination
Connection at default
AVR
Connected
Upper connector of 1TA board (main CPU Connected
board)
Lower connector of 1TA board (main CPU Connected
board)
Upper connector of 1TR board（Power
Connected
sequence board）
Lower connector of 1TR board（Power
Connected
sequence board）
Optional slot 1
Unconnected
Optional slot 2
Unconnected
Optional slot 3
Unconnected
Optional slot 4
Unconnected
Operation panel (Emergency stop switch） Connected
Operation panel (Teach/Repeat switch）
Connected
Teach pendant
Connected
Teach pendant
Connected
Input/Output of 1TB board (Servo board)
Connected
signal
Power supply to 1TB board (Servo board) Connected
Optional operation panel (Optional
Connected (Jumper connector
switches)
is connected as default.）
Optional operation panel (Optional lamps) Unconnected
Additional optional signals
Unconnected
Optional power supply connector 1
Unconnected
Optional power supply connector 2
Unconnected
2.4.1.3 JUMPER SETTINGS
No.
J1
J2
Contents
Switches GND-FG
connection
Switches 24VG-FG
connection
Standard settings
1-2 connected. (GND-FG unconnected.)
2-3 connected. (24VG-FG connected.)
2-16
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.5 1TW BOARD (IO BOARD) (OPTION)
This board is an optional parallel IO board which provides 32 input and 32 output channels, and
is mounted to the optional slot in the card rack.
2.5.1 SPECIFICATIONS
Input Specifications
Number of input 32
channels
Input type
Photo coupler
Input voltage
rating
Input voltage
range
Input current
rating
DC24 V
Maximum
simultaneous
input channels
Common system
100 % ON
(16 channels/common)
simultaneously
16 channels/common
(+ common)
DC24 V ± 10 %
10 mA
Output Specifications
Number of output
32
channels
Output type
Photo coupler insulated
transistor array
Output voltage
DC24 V
rating
Load voltage range DC24 V ± 10 %
Maximum load
current
Maximum surge
current
Maximum
simultaneous
output channels
Common system
0.1 A/channel
(1.6 A/common)
0.4 A/channel
100 % ON
(16 channels/common)
simultaneously
16 channels/common
(- common)
Up to four 1TW boards can be used. But since there are four slots available for optional boards
in the card rack, the number of the 1TW boards is limited depending on the number of other
optional boards to be mounted.
The DC24 V for external equipment is not supplied from the controller; thus, be sure to prepare
DC24 V power when IO board is connected.
For connection with the external equipment, refer to Installation and Connection Manual and
External I/O Manual.
2-17
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.5.2 CONNECTORS, LEDS, CHECK PINS AND SWITCHES
2.5.2.1 LAYOUT
CN3
CN4
CN1
CN2
TP2
CN5
LD2
LD1
4
3
2
SW5
SW3
SW4
SW2
1
ON
CN6
CN7
4
3
2
1
TP1
SW1
ON
P1
Outline view of 1TW board
2.5.2.2 CONNECTORS
No.
CN1*
CN2
CN3*
CN4
CN5*
CN6*
CN7
Contents
Connector for analog output
Output connector
Arc IO connector
Input connector
Connector for connecting arc IO optional board
Connector for connecting arc IO optional board
For debug
Destination
External wiring
External wiring
XSOL
External wiring
Arc IO optional board
Arc IO optional board
-
NOTE* CN1, 3, 5, 6 are mounted when optional analog output is used.
2-18
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.5.2.3 LEDS
No.
Contents
LD1 (ACCESS) Accessing system bus.
Bus access watch dog error is
LD2 (WDERR)
occurring.
Color
Lighting condition
Green ON at normal state
OFF at normal state,
Red
ON at abnormal state
2.5.2.4 CHECK PINS
No.
TP1
TP2
Contents
Ground (GND)
Analog ground (AGND)
2.5.2.5 SWITCHES
No.
SW1-1
SW1-2
Functions
Address settings on boards
1st board
2nd board
3rd board
SW1-3
SW1-4
Standard setting
Settings as in the left cell.
4th board
Optional reset function settings*
ON: Optional reset enabled
OFF: Optional reset disabled
Unused
OFF: Disabled
OFF（Modification prohibited）
2-19
E Series Controller
Kawasaki Robot Troubleshooting Manual
SW2-5
2. Description of Controller
Output voltage range settings of:
SW2- Analog output CH1
SW3- Analog output CH2
SW4- Analog output CH3
SW5- Analog output CH4
Output voltage 0 - 10 V
Settings are as follows:
1. 0 - +10 V
2. 0 - +15 V
3. minus 10V - +10 V
NOTE* By optional reset function, all the outputs become OFF when an access to the 1TW board
via bus is not made for a certain period of time.
2-20
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.5.2.6 PIN ASSIGNMENT
CN2
CN4
1
19 COM2
OUT 1
20
OUT17
21
OUT18
NC
OUT 2
36
OUT 3
35
3
22
OUT19
4
OUT20
5
OUT 4
23
OUT21
OUT 6
OUT22
OUT23
OUT 7
31
OUT 8
30
8
27
OUT24
9
OUT25
10
OUT 9
28
OUT26
OUT11
OUT27
OUT28
OUT12
26
OUT13
25
13
32
OUT29
14
OUT30
15
OUT31
16
OUT14
33
OUT32
36 COM1
(OUT1∼16)
37 COM2
(OUT17∼32)
IN30
14
IN29
13
IN16
IN15
IN14
IN13
IN28
12
IN27
11
IN26
10
IN25
9
IN24
8
IN12
IN11
IN10
IN 9
IN 8
IN23
7
IN22
6
IN21
5
IN20
4
IN19
3
IN18
2
IN 7
IN 6
IN 5
23
OUT16
35
IN31
15
NC
24
OUT15
34
16
27
12
31
IN32
28
11
30
17
29
OUT10
29
NC
32
7
26
(IN1∼16)
33
6
25
18 COM1
34
OUT 5
24
(IN17∼32)
37
2
IN 4
22
17
NC
IN 3
21
18 VIN1
(OUT1∼16)
IN 2
20
19 VIN2
IN17
OUT17∼32)
1
IN 1
The figure above depicts pin arrangements of the connectors on the printed board side. Types of
connectors for the harness are as follows.
Connector body : for CN2
17JE-13370-02(D1)A (DDK) or equivalent
for CN4
17JE-23370-02(D1) (DDK) or equivalent
2-21
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.6 1FG/1HG BOARD (BATTERY BACKUP BOARD FOR ENCODER)
2.6.1 1FG BOARD
2.6.1.1 MAIN FUNCTIONS
This printed board is built inside the base of large-sized robots, and it performs the following
functions:
1. Supplies power to the encoder by converting the +12 V supplied from the controller to +5 V
while the controller power is ON.
2. Supplies power from the battery to keep the position data stored in the encoder while the
controller power is OFF.
3. Detects the battery voltage drop, and alerts the controller.
4. Relays signals (axis restriction limit switch, etc.) detected in the robot arm.
2.6.1.2 LAYOUT
CN
13
CN
12
Battery
TPG
TP1
TP2
CN
11
CN8
CN
10
TP4
TPG2
TP5
TP3
CN
9
CN1
CN2
CN3
CN4
CN5
2-22
CN6
CN
7
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.6.1.3 CHECK PINS
No.
TP1
TP2
TP3
TP4
TP5
TPG
TPG2
Function
Checks +12 V voltage supplied from the controller.
Checks +5 V voltage supplied to the encoder.
Checks voltage supplied to the encoder. +5 V (ON)/Battery (OFF)
Checks battery voltage.
Checks +24 V voltage.
Grounds for +5 V, +12 V and battery.
Ground for +24 V.
2.6.1.4 CONNECTORS
No.
CN1
CN2
CN3
CN4
CN5
CN6
CN7
CN8
Destination
JT1 encoder
JT2 encoder
JT3 encoder
JT4 encoder
JT5 encoder
JT6 encoder
JT7 encoder
Controller
Arm ID board (DC24 V for IO signals and data
CN9
communication)
CN10
Battery
CN11
Axis restriction limit switch *
CN12
Axis restriction limit switch *
CN13
Axis restriction limit switch *
NOTE* See the following figure for the connection.
CN11
1
LS1+
2
3
CN12
4
1
2
3
Short circuit
connector
CN13
4
LS2+
1
2
LS1-
2-23
3
4
LS2-
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.6.2 1HG BOARD
2.6.2.1 MAIN FUNCTIONS
This printed board is built inside the base of small-sized robots, and it performs the following
functions:
1. Supplies power to the encoder by converting the +12 V supplied from the controller to +5 V
while the controller power is ON.
2. Supplies power from the battery to keep the position data stored in the encoder while the
controller power is OFF.
3. Detects the battery voltage drop, and alerts to the controller.
2.6.2.2 LAYOUT
TP4
CN4
TP3
DC-DC
TP2
CN1
TP5
CN2
2.6.2.3 CHECK PINS
No.
TP1
TP2
TP3
TP4
TP5
Function
Checks +12 V voltage supplied from the controller.
Checks +5 V voltage supplied to the encoder.
Checks voltage to the encoder. +5 V (ON)/Battery (OFF)
Checks battery voltage.
Grounds for +5 V, +12 V and battery
2.6.2.4 CONNECTORS
No.
CN1
CN2
CN3
CN4
Destination
Controller
JT7 encoder
Battery
JT1- JT6 encoder
Contents
+12 V, JT7 encoder signal, Battery alarm
JT7 encoder signal, Power supply
Battery power supply
Encoder power supply
2-24
Battery
TP1
CN3
Transformer
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.7 1PV/1TK BOARD (ARM ID BOARD) (OPTION)
The Arm ID board is of two kinds: 1PV board for Z/M series robot, and 1TK board for R series
robot. Each board needs a daughter board, 1JD/1JE board for the 1PV and 1TY board for the
1TK, to send/receive arm IO signals. Each board performs the following functions:
1. 1PV/1TK boards
Reads/writes data on the built-in flash memory via serial communication with the controller.
2. 1JD/1JE/1TY boards (Machine IO board, option)
Sends/Receives the IO signals via serial/parallel communication with the controller.
2.7.1 1PV BOARD
2.7.1.1 LAYOUT
1PV board
CN2
TP3
TP4
SW1
LD1LD2
1PV: CN3
1JD/1JE: CN1
TP9
CPU
TP1
TP2
CN1
CN2
CN3
1JD/1JE board
Outline view of 1PV board with 1JD/1JE board connected
2.7.1.2 1PV BOARD CONNECTORS
No.
CN1
CN2
CN3
Contents
For machine wiring
Communication on controller side
1JD/1JE board connection
Destination
Customer’s device
1FG board
1JD/1JE board
2-25
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.7.1.3 LEDS
No.
LD1 (RUN)
Color
Green
LD2 (ERR)
Red
Contents
CPU in run state.
Lighting condition
Blink at normal state,
OFF or ON at abnormal state
OFF at normal state,
ON at abnormal state
Error
2.7.1.4 CHECK PINS
No.
TP1
TP2
TP3
TP4
TP9
Function
+24 V
24G
VCC (+5 V)
GND
VDD (+3.3 V)
2.7.1.5 SWITCHES
Switch
SW1
No.
1-5
6
7-8
Default
Function
Software switch for application
Writing prohibited/permitted
For system check(Operation
prohibited)
OFF
OFF (Writing prohibited )
OFF
2.7.1.6 1JD/1JE BOARD CONNECTORS
1JD(NPN, SINK)/ 1JE(PNP, SOURCE) board connectors
No.
Contents
Destination
CN1 1PV board connection
1PV board
CN2 Input, Power supply
Customer’s device
CN3 Input/output, Power supply
Customer’s device
2-26
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.7.2 1TK BOARD
2.7.2.1 LAYOUT
1TK board
CN2
TP4
TP3
CN3
TP5
SW1
LD2
1TK: CN3
1TY: CN1
LD1
CPU
CN2
CN1
TP2
1TY board
Outline view of 1TK board with 1TY board connected
2.7.2.2 1TK BOARD CONNECTORS
No.
CN1
CN2
CN3
Contents
For machine wiring
Communication on the
controller side
1TY board connection
Destination
Customer’s device
1HG board
1TY board
2.7.2.3 LEDS
No.
LD1 (RUN)
Color
Green
LD2 (ERR)
Red
Contents
CPU in run state
Error
Lighting condition
Blink at normal state,
OFF or ON at abnormal state
OFF at normal state,
ON at abnormal state
2-27
TP1
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.7.2.4 CHECK PINS
No.
TP1
TP2
TP3
TP4
TP5
Function
+24 V
24G
VCC (+5 V)
GND
VDD (+3.3 V)
2.7.2.5 SWITCHES
Switch
SW1
No.
1-5
6
7-8
Default
OFF
OFF (Writing prohibited)
OFF
Function
Software switch for application
Writing prohibited/permitted
For system check (Operation
prohibited)
2.7.2.6 1TY BOARD CONNECTORS
1TY board (NPN, SINK/ PNP, SOURCE) connectors
No.
Contents
Destination
CN1 1TK board connection
1TK board
CN2 Output
Customer’s device
CN3 Input, Power supply
Customer’s device
2-28
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.8 ENCODER
There are three encoder models for the E Controller, MK32, M35 and M40, which differ by
installation method to the motor but share the same basic specifications. These electronic
multi-turn absolute encoders output 33 bits of data via serial communication. The 33 bits is the
sum of 17 bits of absolute angle position within one rotation by an optical encoder and 16 bits of
the number of rotations data read via counter counting magnetic pulse/rotation. The counter
data is backed up by a battery.
2.8.1 MAIN FUNCTIONS
The encoder performs the following functions:
1. Motor rotation angle detection
One rotation: 131072 (217) pulses
Number of rotations: 65536 (216) counts
When the motor rotates in the direction of CCW (seen from motor output axis side), the value
counts up.
Response speed is 6000 rpm
2. Communication
Position data is transmitted synchronizing with the data request signal from the servo board.
(Half duplex serial communications and baud rate: 4 Mbps)
3. Operational state per power supply voltage
Encoder operation changes per power supply voltage. There are three types of operations as
follows:
(1) Non-operating state:
All operation stops when power supply is +3.0 V or less.
(2) Backup state:
Rotation counter remains functional at +3.6 V to +5 V of power
supply.
(3) Normal operation state: Detects absolute position within one rotation, counts number of
rotations, and communicates with the controller at +5 V of power
supply.
4. Backup
By the backup of a built-in super capacitor, the rotation counter functions properly for 30
minutes after the 1FG/1HG board (encoder battery backup board) is disconnected.
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Kawasaki Robot Troubleshooting Manual
2. Description of Controller
5. Motor CS signal detection
Detects the magnetic pole position of the motor by installing the encoder at the position where
the rotation origin overlaps with the zero cross point of the motor’s voltage inducing U-phase.
6. Differences between MK32, M35 and M40
Installation method differs depending on the motor. MK32 is for large motors and separation
from the motor is possible. M35 and M40 are for small motors, and separation from the
motor is not possible.
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Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.9 SERVO AMPLIFIER UNIT FOR 6 AXES
The servo amplifier unit for 6 axes consists of servo board, power block boards, and case. The
servo board is mounted under the cover, and the power block boards are mounted on the back of
the servo board.
Case
A
1TB board
(Servo board)
Heatsink
Servo board fixing plate
Cover
Power block board
（Total: 6 boards）
A
View A-A
Front
2.9.1 1TB BOARD (SERVO BOARD)
The 1TB board is the servo board for the E series controller and mounted on the power block by
connectors.
2.9.1.1 MAIN FUNCTIONS
The 1TB board performs the following functions:
1.
2.
3.
4.
Interface function for communication with encoders of 9 axes. (Encoder types: MK32, M35
and M40)
Servo data communication with 1TA board (main CPU board):
Calculates interpolation command receiving the motion plan from the 1TA board, and
processes calculations on the position loop, speed loop and motor current loop of up to 9
axes.
Outputs PWM signals to the power block.
Controls brakes for up to 9 axes.
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Kawasaki Robot Troubleshooting Manual
5.
6.
7.
8.
9.
2. Description of Controller
Communicates with up to three MC units.
Cuts OFF the motor power ON signal to the MC unit when the servo-related hardware error
occurs, an error is detected by servo software(encoder-related errors, etc.), or a
communication error is detected by the 1TB board.
Detects and corrects errors in hardware.
Monitors the axis restriction LS state.
Communicates with the arm ID board.
2.9.1.2 CONNECTORS, JUMPERS, LEDS, CHECK PINS, SWITCHES
2.9.1.2.1 LAYOUT
X512
5 67
0
4
3 21
X508
J2
SW7
12
J9
9
8
5
PUSH
PUSH
J5
X519
J1
CN3
X502
J3
JTAG_CPU
X503
X520 X514
J6
J7
X503
PUSH
J3
J4
1
X510
4
X518
X517
CN2
X515
TP24
X504
X505
X507
SW2
TP23 TP25
Outline view of 1TB board (Front)
ON
TP12
1
TP14
TP13
LD3
LD5
LD1 LD4
TP10
LD11 LD13
TP15
TP11
LD10
LD14
LD2
LD16
LD15
LD12
X509
X506
X511
X513
X501
TP26 LD8 LD9
2-32
2
3
4
5
6
7
8
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
X516-2
X516-4
X516-6
X516-1
X516-3
X516-5
Outline view of 1TB board (Rear)
2.9.1.2.2 CONNECTORS
No.
X501
X502
X503
X504
Contents
DC power supply input
Input/Output to/from boards in the card rack
Input/Output to/from MC unit 1
Input/Output to/from MC unit 2
(Used for two MC units spec.)
Destination
Mother board X207
Mother board X206
MC unit 1 X304
MC unit 2 X304
X505
Input/Output to/from MC unit 3
(Used for three MC units spec.)
Optional communication connector
Optional communication connector
Debug communication connector
Communication with encoder of JT1 - JT6,
Battery alarm input
Safety circuit, IO24 V output
Communication with encoder of JT7,
Battery alarm input
MC unit 3 X304
X3
X3 (Or JT7 signal connector
on the rear side)
Communication with encoder of JT8,
Battery alarm input (Used when JT8 is
JT8 signal connector on the
rear side (Option)
X506
X507
X508
X509
X510
X511
X512
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E Series Controller
Kawasaki Robot Troubleshooting Manual
X513
2. Description of Controller
connected.)
Communication with encoder of JT9,
Battery alarm input (Used when JT9 is
connected.)
X514
X515
X516-1 to 6
X517
Communication with Arm ID board
Optional LS override switch connector
For power block connection
For JT7 power block connection
X518
For JT8 power block connection
X519
For JT9 power block connection
X520
CN2
CN3
Optional connector
For optional board
For optional board
JT9 signal connector on the
rear side (Option)*
X3
Power block X516-1 to 6
JT7 amp. unit for 1 axis X553
(Option)
JT8 amp. unit for 1 axis X553
(Option)
JT9 amp. unit for 1 axis X553
(Option)*
-
NOTE* For E3x/E4x controllers only
2.9.1.2.3 JUMPERS
Contents
No.
J1
For debug
J2
For switching encoder type
J3
For debug
J4
For debug
J5
For debug
J6
For debug
J7
For debug
J9
For debug
JTAG_CPU
For debug
Settings
2-3 connected (modification prohibited)
1-5 connected (modification prohibited)
1-2 connected (modification prohibited)
1-2 connected (modification prohibited)
Unconnected (modification prohibited)
Unconnected (modification prohibited)
Unconnected (modification prohibited)
Unconnected (modification prohibited)
Unconnected (modification prohibited)
2.9.1.2.4 LEDS
No.
Contents
Monitor software on servo board in run
LD1
state.
(MON_RUN)
LD2 (ERR_DC)
Power supply on servo board is abnormal.
2-34
Color
Lighting condition
Green Blinks until servo software
starts running after power is
supplied, then becomes
OFF.
Red
OFF at normal state,
ON at abnormal state
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
LD3 (Tx_STA1) Sending state 1 in servo data
communication (with main CPU board).
LD4
Error “Error reset disable” detected by
(ERR_NRST)
servo board is occurring.
LD5 (Tx_STA2) Sending state 2 in servo data
communication (with main CPU board).
LD8 (+24V)
+24 V power supply on servo board
LD9 (I/O24V)
IO24 V power supply on servo board
LD10 (I LOOP
HW)
Servo FPGA in run state
LD11
(Rx_STA)
LD12
(SV_ERR)
LD13
(SV_RUN)
Receiving state in servo data
communication (with main CPU board).
Servo error is occurring.
LD14
(RGSO_STA)
Servo control is ON.
LD15
(BRK_STA)
LD16
(ERR_WDT)
Motor brake control enabled.
Servo software in run state
Green Blink at normal state,
OFF at abnormal state
Red
OFF at normal state,
ON at abnormal state
Green Blink at normal state,
OFF at abnormal state
Green ON at normal state,
OFF at abnormal state
Green ON at normal state,
OFF at abnormal state
Green Blink at run state
(OFF right after power is
supplied.)
Green Blink at normal state,
OFF at abnormal state
Red OFF at normal state,
ON at abnormal state
Green Blink at run state
(OFF right after power is
supplied.)
Green ON at servo control ON
Watch dog timer error is occurring.
2.9.1.2.5 CHECK PINS
No.
Contents
TP10
3.3 V power supply
TP11
1.2 V power supply
TP12
12 V power supply
TP13
5 V power supply
TP14
1.0 V power supply
TP15
2.5 V power supply
TP23
+24 V power supply
TP24
IO24 V power supply
TP25
24 VG
2-35
Green ON when motor brake
control accepted.
Red OFF at normal state,
ON at abnormal state
E Series Controller
Kawasaki Robot Troubleshooting Manual
TP26
2. Description of Controller
GND
NOTE Check pins other than those above are for debug/measurement.
2.9.1.2.6 SWITCHES
Location
SW2
SW7
Contents
For debug
Servo board number
settings
Settings
OFF for all (modification prohibited)
Standard: 0 (The number changes
depending on the number of servo
boards.)
2.9.1.3 1TB BOARD SOFTWARE
The 1TB board has a CPU, but servo software is installed in the CF card on the 1TA board (main
CPU board). Thus, the data is transmitted from the 1TA to the 1TB when the controller power
is turned ON.
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2. Description of Controller
2.9.2 1TC/1TD BOARD (POWER BLOCK BOARD)
The 1TC and 1TD boards are power block boards: the 1TC is for large-sized motor and
the 1TD is for small-sized motor. One power block board is used in each axis, and 6 boards are
used for the standard 6 axes spec. in the E series controller.
For optional 7, 8 and 9 axes specifications, the 1TC board (for large motor) and the 1TD board
(for small motors) are used in the amplifier unit for one axis. The board controls the power and
drives the AC servomotors receiving the commands from the 1TB board (servo board).
2.9.2.1 MAIN FUNCTIONS
The 1TC/1TD performs the following functions:
1.
2.
3.
4.
5.
Receives PN power supply from the MC unit and uses it as a power.
Receives the PWM (Pulse Width Modulation) commands from the 1TB board (servo board),
and controls the current for the motor by switching the IPM (Intelligent Power Modules).
Detects the current flowing in the motor by the current detection circuit, and feeds back to
the 1TB board.
Sends alarm signals of abnormal power module to the 1TB board when the IPM detects
overcurrent, overheat, etc.
Sets power block code by mounting the 0 Ω resistors RJ1 - RJ4. If the model setting in the
software and this code do not match, an error occurs.
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Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.9.2.2 CONECTORS, CHECK PINS
2.9.2.2.1 LAYOUT
X516
TP8
TP6
TP2
TP4
P
TP7
TP1
TP3
TP5
X552
N
X551
Outline view of 1TC board
X516
TP6
X552
TP5
TP4 TP3
P
TP2 TP1
TP8 TP7
N
X551
Outline view of 1TD board
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Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.9.2.2.2 CONNECTORS (FOR 1TC/1TD)
No.
X516
X551
X552
P
N
Function
Remakrs
PWM signal, current feedback, error signal
Output to motor (U, V, W)
IPM control power input (DC20 V)
PN power supply input (P) in main circuit
PN power supply input (N) in main circuit
Threaded terminal
Threaded terminal
2.9.2.2.3 CHECK PINS (FOR 1TC/1TD)
No.
TP1
TP2
Function
Remarks
IPM control power supply (W phase, ＋)
IPM control power supply (W phase, －)
TP3
TP4
TP5
TP6
TP7
TP8
IPM control power supply (V phase,
IPM control power supply (V phase,
IPM control power supply (U phase,
IPM control power supply (U phase,
IPM control power supply (N phase,
IPM control power supply (N phase,
＋)
－)
＋)
－)
＋)
－)
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E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.10 AMPLIFIER UNIT FOR SINGLE AXIS
This unit is single axis power block for the external axis and can additionally be mounted inside
the controller. There are four kinds of units: two for large motors (1TC board built-in), and two
for small motors (1TD board built-in). The unit is composed of power block unit (1TC/1TD
board), connector board(1TL board) and case.
1TL board
1TC/1TD board
Case
A
X566
X563
X564
X562
X565
X551
A
View A-A
Front
2.10.1 SPECIFICATIONS
Item
Built-in board
Number of axis
Power block rated output
Specification
For large motor
1TC board
Single axis
100 A
50 A
For small motor
1TD board
Single axis
30 A
15 A
2.10.2 MAIN FUNCTIONS
Refer to 1TC/1TD board of Servo amplifier unit for 6 axes for the functions.
2.10.3 CONNECTORS
No.
Function
X551
Power supply to motor (connected to separate harness)
X562
PN power supply input
X563
PN power supply/power distribution
X564
20 V control power supply/power distribution
X565
20 V control power supply input
X566
Signal connector of PWM, etc. (connected to either X517(JT7), X518(JT8), or
X519(JT9) of servo board)
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E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.11 DC POWER SUPPLY FOR CONTROL (AVR)
The AVR (Auto Voltage Regulator) unit is housed in the left part of the card rack, and supplies
control power to each board via the 1TX board (mother board).
2.11.1 SPECIFICATIONS
Input
Rated capacity
200 - 240 VAC/
1.25 A, 50/60 Hz
Maximum rating 280 VAC
Range
160 - 265 VAC
Output (S82W-624)
+5 VDC
11 A
+12 VDC
+3.3 VDC
+24 VDC
3.0 A
4.0 A
3.5 A
2.11.2 MAIN FUNCTIONS
The DC power supply for control (AVR) performs the following functions:
1. Converts input AC power into AC/DC power, and supplies +3.3 V, +5 V, +12 V, +24 V
necessary for each board.
2. Detects AC input power errors, and alerts the 1TR board. There are three types of detection
as follows.
(1) Detection of instant power failure
Detection level is 130 to 145 VAC or less. When this state continues for 25 to 35 msec, an
error signal is output to the 1TR board.
(2) Detection of over-voltage
Detection level is 267 to 283 VAC or more. When this state continues for 1 to 2 sec. or
more, an error signal is output to the 1TR board.
(3) Detection of low voltage
Detection level is 148 to 158 VAC or less. When this state continues for 1 to 2 sec. or more,
an error signal is output to the 1TR board.
3. Shuts down when the DC voltage on the output side is overloaded (outputs 105 % or more of
the rated capacity continuously for 5 sec. or more) or over-voltage state occurs (115 % - 130 %
of the rated capacity). It can be restored by re-inputting the power in 10 sec. or more after
shutdown.
4. Turns ON/OFF the DC output by the remote signal from the 1TR board.
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Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.11.3 CONNECTORS AND OUTPUT VOLTAGE ADJUSTMENT
2.11.3.1 LAYOUT
CN1
AVR
+5 V adjustment
+3.3 V adjustment
AVR front
2.11.3.2 CONNECTORS
CN1(X201): AC210 V input
2.11.3.3 OUTPUT VOLTAGE ADJUSTING KNOB
The +5 V and +3.3 V adjusting knobs are provided on the front of the AVR.
(For the +12 V and +24 V, output voltage is not adjustable.)
！
CAUTION
1. Normally, avoid touching these adjusting knobs.
2. When checking the output voltage, use the check pins on the following
boards.
Voltage
Board
Check pin
Normal range
+5 V
1TR board
TP4(GND)-TP1
+5.05 - +5.15 V
+12 V
1TR board
TP4(GND)-TP3
+12.25 - +12.75 V
+3.3 V
1TR board
TP4(GND)-TP2
+3.25 - +3.35 V
+24 V
1TR board
TP6(GND)-TP5
+23.9 - +24.7 V
3. When adjusting the voltage, rotate the adjusting knob slowly. Rapid
rotating may damage the AVR.
！
DANGER
Before removing the AVR unit from the card rack, cut OFF the external
power supply and wait at least 3 minutes so that the output voltage
becomes 0.
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2. Description of Controller
2.12 MC UNIT
The MC unit consists of 1TU board (MC power module), 1TQ/1TV boards (MC control board),
magnetic contactor (MC), inrush current preventing resistor, power supply for power module,
MC unit fan, and case, etc.
Case
Fan
A
Power supply for power module
1TV board
Magnetic contactor
1TU board
1TQ board
(MC)
A
View A-A
MC unit front
Capacitor
2.12.1 1TU BOARD (MC POWER BOARD)
This board is mounted in the rear part of the MC unit, and generates PN power from the AC210
V, controls regeneration, and generates brake power, etc.
2.12.1.1 MAIN FUNCTION
1.
2.
3.
4.
5.
6.
7.
Sends/receives signals to/from the 1TQ/1TV boards (MC control board).
Outputs PN power generated from the AC210 V to the servo amplifier unit.
Controls inrush current by receiving the commands from the 1TQ/1TV boards (MC control
board).
Monitors the PN voltage and notifies the 1TQ/1TV boards of the abnormal state.
Connects the AC40 V input from power transformer to the diode bridge on the 1TU board,
and generates DC24 V for brake power supply.
Performs regenerative control. Also, notifies the 1TQ/1TV boards of the abnormal state in
the thermal switch of the regenerative resistor.
Monitors 20 V voltage for the power module and notifies the 1TQ/1TV boards of the
abnormal state.
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Kawasaki Robot Troubleshooting Manual
8.
2. Description of Controller
Monitors thyristor module temperature for PN power generation and notifies the 1TQ/1TV
boards of the abnormal state.
2.12.1.2 CONNECTORS, LEDS, CHECK PINS
2.12.1.2.1 LAYOUT
X354
LD1
X351
X352
X353
X356
TP2
TP1
X357
TP4
TP5
X362
X355
X359
TP3
X358
X361
X360
TP7
TP6
TP8
TP9
Outline view of 1TU board
2.12.1.2.2 CONNECTORS
No.
X351
X352
X353
X354
X355
Contents
AC210 V 3 φ input
P-N power supply output for 6 axes
amp.
P-N power supply output for single
axis amp.
Regenerative resistor, thermal
switch connection
Inrush current preventing resistor
connection
2-44
Destination
Magnetic contactor in MC unit
P-N terminal in servo amp. unit for 6 axes
Amp. unit for single axis X562
Regenerative resistor (XRS connector)
Inrush current preventing resistor in MC unit
E Series Controller
Kawasaki Robot Troubleshooting Manual
2. Description of Controller
X356
P-N power supply smoothing
capacitor connection
X357
X358
DC20 V input
20 V power supply in MC unit
DC20 V output for 6 axes amplifier Power block board in servo amplifier unit for
6 axes
DC20 V output for single axis
Amplifier unit for single axis X565
amplifier
Transformer for brake power supply
AC40 V 1 φ input
Brake power supply output
1TV board X320 in MC unit
MC unit internal signal
1TV board X306 in MC unit
X359
X360
X361
X362
Smoothing capacitor in MC unit
2.12.1.2.3 LEDS
No.
LD1
Contents
P-N power supply
Color
Lighting condition
Orange ON when supplying P-N
power
2.12.1.2.4 CHECK PINS
No.
Contents
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
P
N (GND for P-N power supply)
10 V
20 V
15 V
BR24 V
BR24G
BR15 V
TP9
BR15G
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Kawasaki Robot Troubleshooting Manual
2. Description of Controller
2.12.2 1TQ/1TV BOARDS (MC CONTROL BOARD)
The boards are MC control boards of the E series controller and mounted in the front part inside
the MC unit. The 1TQ and 1TV boards are connected directly by a board-to-board connector
and are used as a pair. The 1TQ board mounts a CPU, and communicates with the 1TB board
(servo board) via RS485.
2.12.2.1 MAIN FUNCTIONS
1. Sends/receives signals to/from the 1TB board (servo board) via serial communication.
2. Controls safety relay and MC(Magnetic contactor), and monitors safety circuits and detects
abnormalities.
3. Sets the number of safety circuits (double circuit as standard). To change the setting, switch
settings on the 1TR board (power sequence board) is also necessary.
4. Controls ON/OFF for the inrush current control relay on the 1TU board (MC power board).
5. Monitors brake power supply voltage and detects abnormalities.
6. Detects abnormal signals from the 1TU board (regenerative thermal switch, thyristor thermal
switch, abnormal 20 V power supply, etc.). Also, receives regenerative state signals from
the 1TU board and detects abnormalities if any.
7. Monitors PN voltage values from the 1TU board. Also, detects any abnormalities in the
PN voltage.
8. Distributes power for fan. Also, monitors signals of the number of fan rotations and detects
the number of rotations.
9. Controls ON/OFF of the fan power for the servo amplifier.
10. Controls motor brake for up to 9 axes by receiving signals from the 1TB board.
11. Notifies AS software of the abnormal state, such as disconnection/short-circuit, of the brake
line.
12. Detects abnormalities in the motor thermal line (disconnection of separate harness).
13. Allows connections of manual brake release switches (option) for up to 9 axes.
14. Allows connections of hour meter (option).
15. Allows to output servo ON lamp contact signals.
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2. Description of Controller
2.12.2.2 CONNECTORS, JUMPERS, LEDS, CHECK PINS, SWITCH
2.12.2.2.1 LAYOUT
1TQ board
TP6
TP7
X302
TP8
TP19
TP18
TP2
X303
X309
TP14
TP1
JP4
X304
1
2
3
TP12
ISP1
TP5
TP4
TP3
TP17
TP15 TP16
X308
SW1
JP1
X305
JP4
X301 X307
TP13
Rear
LD17
LD13
LD14
LD2
LD1
LD8
LD7
LD11
LD10
LD9
LD5
LD4
LD3
LD16
LD6
LD15
LD12
Front
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2. Description of Controller
1TV board
X320
X316
X315
X309
X317
X318
X319
TP9
X312
TP10
X313
X311
TP11
X314
JP3
JP2
X306
Front
Rear
2.12.2.2.2 CONNECTORS
No.
X301
X302
X303
X304
X305
X306
X307
X308
X309U
X309L
X311
X312
Contents
Contact input for external control of MC
unit
Fan connection
(Card rack, servo amp., MC unit)
Destination
External circuit (Jumper connector
is connected as default.)
Fan1 - 6 in controller
Optional fan connection
Optional fan
Servo board input/output signal
1TB board: X503
Debug communication
Internal signal of MC unit
1TU board: X362
Servo ON lamp connection
External servo ON lamp (option)
Hour meter connection
Hour meter (option)
1TQ-1TV boards connection
X309L
1TQ-1TV boards connection
X309U
MC(magnetic contactor) connection
MC (magnetic contactor)
Connection between MC units (when two X313 of the next number of MC
or more MC units are used.)
unit (option)
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Kawasaki Robot Troubleshooting Manual
2. Description of Controller
X313
Connection between MC units (when two X312 of the previous number of
or more MC units are used.)
MC unit (option)
X314
X315
X316
X317
Thermal switch connection in robot arm
Brake release switch connection
JT1 - 6 brake connection
JT7 brake connection, confirmation of JT7
connection
Separate motor harness connector
Brake release switch (option)
Separate motor harness connector
Separate motor harness connector
or rear side connector for JT7
(option)
X318
JT8 brake connection, confirmation of JT8
connection
JT9 brake connection, confirmation of JT9
connection
Rear side connector for JT8
(option)
Rear side connector for JT9
(option)*
Brake power supply input
1TU board: X361
X319
X320
NOTE* For E3x/E4x controllers only
2.12.2.2.3 JUMPER SETTINGS
No.
Contents
JP1
For debug
JP2
JP3
For switching the number of safety circuits
JP4
Software writing setting
ISP1
For debug
Settings
Unconnected (modification
prohibited)
Double circuit when JP2 is
connected.
Single circuit when JP3 is
connected.
1-2 connected (modification
prohibited)
Unconnected (modification
prohibited)
2.12.2.2.4 LEDS
No.
LD1(RUN)
LD2(ERR_CPU)
LD3(KS1)
LD4(KS2)
Contents
CPU on 1TQ board in run state
Abnormal state in 1TQ board
Color
Lighting condition
Green Blink at run state
Red OFF at normal state,
ON at abnormal state
Safety relay (KS1) on 1TV board in Green ON at run state
run state
Safety relay (KS2) on 1TV board in Green ON at run state
run state
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2. Description of Controller
LD5(KS3)
Safety relay (KS3) on 1TV board in Green ON at run state
run state
LD6(STG)
LD7(KS_EX1)
Requesting motor power supply ON
Safety relay (KS_EX1) for
explosion-proof on 1TV board in run
state
Safety relay (KS_EX2) for
explosion-proof on 1TV board in run
state
Green ON when requested.
Green ON at run state
MC(magnetic contactor: K1) in run
state
MC(magnetic contactor: K2) in run
state
Green ON at run state
LD8(KS_EX2)
LD9(K1)
LD10(K2)
LD11(K3)
Green ON at run state
MC(inrush current preventing relay: Green ON at run state
K3) in run state
P-N power supply
Green ON at rated value (150
V) or above
LD12(PN_STS)
LD13(ERR_PS)
Safety circuit in abnormal state
LD14(ERR_SYS)
Supplying power to board
LD15(RDY_PWR)
LD16(EN_PWR)
LD17(ERR_WDT)
Motor power supply ON state
Safety circuit state
CPU watch dog error state
2.12.2.2.5 CHECK PINS
No.
Green ON at run state
TP3
TP4
TP5
TP6
TP7
TP8
Contents
5 V power supply
3.3 V power supply
GND
Brake power supply
Brake power supply
Brake power supply GND
TP9
TP10
TP11
Power supply for brake control
Brake power supply GND
Brake power supply
2-50
Red
OFF at normal state,
ON at abnormal state
Red OFF at normal state,
ON at abnormal state
Green ON at motor power ON
Green ON at normal state
Red OFF at normal state,
ON at abnormal state
E Series Controller
Kawasaki Robot Troubleshooting Manual
TP15
TP16
TP17
TP18
2. Description of Controller
12 V power supply
+24 V
24 VG
12 V power supply
NOTE Check pins other than those above are for debug/measurement.
2.12.2.2.6 SWITCH
No.
SW1
Contents
For debug
Setting
OFF for all (modification prohibited)
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2. Description of Controller
2.13 MANUAL BRAKE RELEASE SWITCH (OPTION)
This switch manually releases the electromagnetic brake mounted in the motor for robot.
Release enable switch
Front
Right side
！
DANGER
When no servo power is applied, electromagnetic brakes lock to maintain the robot
arm posture. When the brake is manually released by operating this release switch,
the arm may fall, especially in the axes bearing loads. Be careful and always
support the arm firmly (by crane, etc.) before using manual brake release SW.
！
WARNING
Position yourself to observe the entire robot arm and
keep your eyes on the arm when operating this switch.
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2. Description of Controller
Operating Procedure:
1. Turn OFF the motor power.
2. Press and hold down the RELEASE ENABLE switch.
3. Press the switch corresponding to the axis in which the brake is to be released (JT1, JT2…).
The brake for that axis is released. If either switch is released, the electromagnetic brake
relocks.
！
CAUTION
Stop using the manual brake release SW immediately if the
electromagnetic brake is released by pressing only one switch. The
switch may be defective.
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2. Description of Controller
MEMO
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3. Troubleshooting
3.0 TROUBLESHOOTING
When troubles occur, they are normally solved based on the error messages that are displayed.
However, for some troubles, messages cannot be displayed due to initial troubles such as
controller power failure or teach pendant screen malfunction, etc.
This chapter divides the errors into two types: initial troubles which can/do not display error
messages, and steady-state troubles which output an error message, and describes the causes and
countermeasures for each type of errors.
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Initial Troubles and Countermeasures ･････････････････････････････････････････
Initial Trouble 1: Controller power Does Not Turn ON ･･････････････････････････
Initial Trouble 2: Teach Pendant Is Not Operable ･･･････････････････････････････
Initial Trouble 3: Motor Power Does Not Turn ON ･････････････････････････････
Initial Trouble 4: Robot Does Not Move ･･･････････････････････････････････････
Steady-State Troubles and Countermeasures ･･･････････････････････････････････
3-2
3-2
3-5
3-7
3-8
3-9
Error Classification･･････････････････････････････････････････････････････････ 3-9
Error Handling by Robot････････････････････････････････････････････････････ 3-10
Further Error Classification and Error Numbers ･･･････････････････････････････ 3-11
Error Display ･･････････････････････････････････････････････････････････････ 3-12
Error List･･････････････････････････････････････････････････････････････････ 3-12
Common Error Examples ･･･････････････････････････････････････････････････ 3-13
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3. Troubleshooting
3.1 INITIAL TROUBLES AND COUNTERMEASURES
This section describes the following most common initial troubles.
3.1.1 Initial Trouble 1: Controller power Does Not Turn ON
3.1.2 Initial Trouble 2: Teach Pendant Is Not Operable
3.1.3 Initial Trouble 3: Motor Power Does Not Turn ON
3.1.4 Initial Trouble 4: Robot Does Not Move
3.1.1 INITIAL TROUBLE 1: CONTROLLER POWER DOES NOT TURN ON
This occurs when the system does not activate even if the CONTROLLER POWER (NFB
(No-Fuse Breaker)) of the controller is turned ON. In the examples below, the controller power
switch is referred to as the CONTROLLER POWER.
1. When turning ON the CONTROLLER POWER of the controller, the NFB has immediately
tripped.
2. The CONTROLLER POWER in the controller can be turned ON, but the controller power
lamp on the operation panel does not light up.
Details of each case are described below.
Case1: When turning ON the CONTROLLER POWER of the controller, the NFB is
immediately tripped.
This occurs when controller power is not supplied to the controller because the NFB in the
controller has immediately tripped (turned OFF), even though CONTROLLER POWER was
turned ON.
Main cause:
1. The AC power line is short-circuited in the controller, and the controller power switch detects
overcurrent and then it has tripped.
2. Defect in the controller power switch.
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3. Troubleshooting
Countermeasure:
！
DANGER
1. Before operation, be sure to intercept the external power switch so that the
external power supplied to the controller is shut OFF.
2. Display signs stating clearly “POWER CUT-OFF IN PROGRESS” or
“TROUBLESHOOTING IN PROGRESS”, and take measures to prevent
personnel from accidentally turning ON the power (tag or lock out power
switches, etc.).
1. Cut OFF the CONTROLLER POWER and then check the followings for short-circuit with a
tester (voltmeter).
R: S
R: FG
S: T
S: FG
T: R
T: FG
If there is any short-circuit after checking, replace the parts, such as controller harness,
transformer, etc.
2. Replace the controller power switch.
Case2: CONTROLLER POWER in the controller can be turned ON, but the controller
power lamp on the operation panel does not light up.
This occurs when the system does not activate properly because of an abnormality in the external
power supplied to the controller or in the power supply circuit of the controller.
Main cause:
1. The external power voltage supplied to the controller deviates from the specified value, the
external power supply/input cable is disconnected, or the external power is not supplied.
2. Power is not supplied to the AVR.
3. The power is not supplied to the controller power lamp due to a defect in the AVR, mother
board, or the lamp itself.
4. Failure in the external control power wiring for the power sequence board.
5. Defect such as disconnection, short-circuit, etc. of the wiring in the controller.
6. Immediately prior to the trouble occurrence, AVR security function for overcurrent/
overvoltage has been activated.
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3. Troubleshooting
Countermeasure:
1. Check the specification of the external power voltage, and then check the external power
supply/input cable and the external power voltage.
2. Check the connection of the power connector to the AVR.
3. Check the output power voltage of the AVR, and check for defects in the controller power
lamp. Replace them if necessary.
4. Check for faults in the external control power wiring.
5. Check the wirings between NFB and AVR, and between mother board and controller power
lamp in the controller. Also, check for any abnormality in the +12 V power supply with
check pins on the power sequence board.
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3.1.2
3. Troubleshooting
INITIAL TROUBLE 2: TEACH PENDANT IS NOT OPERABLE
This is the state where the teach pendant is not operable even if the CONTROLLER POWER of
the controller is turned ON and the controller power is ON. The following three cases can be
considered.
1. The controller power lamp lights ON, but the teach pendant screen is not displayed. (Back
light does not turn ON.)
2. The back light of the teach pendant turns ON, but the screen is not displayed.
3. The screen of the teach pendant is displayed, but operations such as key input or AS command
are not possible.
Details of each case are described below.
Case1: The controller power lamp lights ON, but the teach pendant screen is not
displayed. (Back light does not turn ON.)
DC power supply is normal in the controller, but if no power is supplied to the teach pendant, the
screen is not displayed and the back light does not turn ON.
Main cause:
1. +12V power is not supplied to the teach pendant.
2. Defective parts in the teach pendant, such as LCD, printed board, etc.
3. Disconnection or short-circuit in the cable between the teach pendant and the controller.
Countermeasure:
1. Check whether the cable of the teach pendant is properly connected to the connector.
2. Replace the teach pendant.
3. Replace the cable of the teach pendant.
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3. Troubleshooting
Case2: The back light of the teach pendant turns ON, but the screen is not displayed.
When the backlight is ON, the power is supplied to the teach pendant, but the teach pendant
screen does not display any characters.
Main cause:
1. Defect in the teach pendant.
2. Disconnection of the harness to the teach pendant.
3. Defect in the main CPU board.
Countermeasure:
1. Replace the teach pendant.
2. Check the harness to the teach pendant.
3. Replace the main CPU board.
Case3: The screen of the teach pendant is displayed, but operations such as key input or
AS command are not possible.
This occurs when the key information that was input does not reach the main CPU board, or data
from the main CPU does not reach the teach pendant.
The key information input by the teach pendant is transmitted to the main CPU board via the path
described below.
Mother board
Display device
1KX/1NX
board
1TX board
Main
CPU
Main
CPU
board
Input
keys
1KA
board
1TA board
Teach pendant
Main cause:
1. Defect in the teach pendant.
2. Disconnection of the harness to the teach pendant.
3. Defect in the main CPU board.
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3. Troubleshooting
Countermeasure:
1. Replace the teach pendant.
2. Check the harness to the teach pendant.
3. Replace the main CPU board.
3.1.3 INITIAL TROUBLE 3: MOTOR POWER DOES NOT TURN ON
This occurs when the motor power cannot be turned ON even after pressing the MOTOR ON
button on the teach pendant.
Main cause:
1. An error has occurred.
2. Emergency Stop is in effect.
Countermeasure:
1. When the error message is displayed, check the content of the error and take appropriate
measures to fix the error.
2. Confirm that all Emergency Stop switches are released.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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3. Troubleshooting
3.1.4 INITIAL TROUBLE 4: ROBOT DOES NOT MOVE
This is the state when the robot does not move even though motor power is ON.
Main cause:
1. External hold is in effect.
2. An error has occurred.
3. X210 connector of the mother board is not connected.
4. The brake of the motor is not released.
5. CHECK GO (step forward key) on the teach pendant was not pressed in check mode, or the
TRIGGER switch was released.
6. Robot is waiting for signals to be input in repeat mode, such as signals for cycle start, step
forward, program change, WX, jump, etc.
Countermeasure:
1. Release the external hold.
2. When the error message is displayed, check the content of the error and take appropriate
measures to fix the error.
3. Check the connection of the X210 connector of the mother board.
4. Replace the servo amplifier unit or MC unit. Also, check the harness between the servo board
and MC unit.
5. If the robot is in check mode, press CHECK GO (step forward key), the TRIGGER switch, etc.
on the teach pendant.
6. If in repeat mode, input the signal and break the waiting state.
！
DANGER
Robot may move suddenly when stop conditions are released.
Do not approach robot even when it appears to be stopped.
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Kawasaki Robot Troubleshooting Manual
3. Troubleshooting
3.2 STEADY-STATE TROUBLES AND COUNTERMEASURES
Once a robot starts to move, error messages will be displayed for most assumable troubles. To
solve these troubles, follow the messages. If a trouble occurs under conditions which cannot be
assumed, no error messages will be displayed. In this case, please contact the nearest KHI
service center or branch office with the details of this trouble.
3.3 ERROR CLASSIFICATION
When an assumable error occurs, the code and message for that error is displayed and error is
classified into the following four types depending on its condition and seriousness. Error codes
are displayed with the letter, P, W, E or D in front (representing the error type) followed by a
four-digit number.
1. P: Operation error
Errors caused by operation mistakes. This type of error does not affect robot motion.
Example: “P0126 Illegal switch name.”
2. W: Warning
This is not yet an error but may cause an error if left unfixed.
Example: “W1013 Encoder battery low voltage.”
3. E: Minor failure
This is a minor failure which essentially can be recovered by the error reset function
without turning OFF/ON the controller power supply after the cause of error is removed.
Example: “E1082 Out of absolute lower limit.”
4. D: Major failure
This is a serious error involving hardware, software or peripheral devices which essentially
cannot be recovered by the error reset function, and its recovery requires turning OFF/ON
the controller power supply.
Example: “D1528 Controller temperature is out of range.”
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3. Troubleshooting
3.4 ERROR HANDLING BY ROBOT
The following table shows how the robot processes each error type.
Error
type
Error lamp
ON*
Cycle start
OFF
Motor power
OFF
P
W
E
D
X
X
X
Δ
Δ
O
O
O
O
Processing of each error type
Δ
Δ
O
Symbols indicating measures to be performed are as follows.
X: not executed
O: executed
Δ: depending on the error content
NOTE* For the controller with optional operational panel only.
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3. Troubleshooting
3.5 FURTHER ERROR CLASSIFICATION AND ERROR NUMBERS
Errors are further subdivided into the items shown in the table below, and each is assigned with
four-digit error numbers. The following classification commonly applies to all the error types of
P, W, E and D.
Error Category
Error No.
Serious error
0001 - 0099
Grammatical error
0100 - 0899
Memory
0900 - 0999
Common error
1000 - 3999
Communication
4000 - 4999
Spot
5000 - 5499
Vision
5500 - 5999
Painting
6000 - 6499
Arc
6500 - 6999
Others
500 items
Error category and error No.
Also, common errors are divided as shown in the table below per P/W/E/D.
P
W
E
D
Program execution operation
Others
Standard
Standard
Servo related
1000 - 1999
2000 - 3999
1000 - 3999
1000 - 3999
1000 - 1499
Encoder, amplifier related
Others
1500 - 1999
2000 - 3999
Details of common error
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3. Troubleshooting
3.6 ERROR DISPLAY
Error messages are displayed on the LCD of the teach pendant and the screen of the PC via the
terminal software (KRterm/Kcwin32).
On the teach pendant, operation errors (P) are displayed in the system message area, and other
errors are shown by the pop-up screen. The figure below is a sample error pop-up screen
displayed on the LCD of the teach pendant.
Error pop-up
screen
3.7 ERROR LIST
Refer to Error Message List attached as appendix.
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3. Troubleshooting
3.8 COMMON ERROR EXAMPLES
This section describes the contents, main causes, and countermeasures for the most typical errors
requiring explanation in order of their code number.
Items listed below in the left column are given under “Error message” on the following pages.
Item
Description
Error processing Robot process at time
the error occurred.
Error reset
Is recovery possible
by pressing error reset
button?
Classification
Display
Cycle stop
Motor power
OFF
Controller
power OFF
Acceptable
Non-acceptable
3-13
Displays error message only.
Cycle start stops.
Turns motor power OFF.
Turns controller power OFF
internally.
Remove the error cause, press the
<Reset> on the teach pendant (and
MOTOR ON/ A+CYCLE START
buttons on the teach pendant if
necessary), then operation can be
continued.
Remove the error cause, then turn
the CONTROLLER POWER OFF
→ ON.
E Series Controller
Kawasaki Robot Troubleshooting Manual
3. Troubleshooting
Error code
: D0001
Error message : CPU error. (PC=XX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The CPU of the main CPU board stopped functioning. (Detected by AS software)
Main cause:
Defect in the main CPU board.
Countermeasure:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. If the program does not return to normal, execute initialization and reload the teach data.
Take note that if the teach pendant or the terminal software on the PC is not running at this
time, initialization cannot be done.
3. Replace the main CPU board if the error cannot be resolved.
4. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
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3. Troubleshooting
Error code
: D0007
Error message : [Servo boardXX]CPU error. (CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
An exceptional process was performed in the servo board CPU.
Main cause:
Defect in the servo board.
Countermeasure:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. Replace the servo board if the error cannot be resolved.
3. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
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3. Troubleshooting
Error code
: D0008
Error message : [Servo boardXX]Floating point exception. (CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Floating-point calculations which result in indefinite value are performed in the servo software.
Main cause:
Defect in the servo software.
Countermeasure:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. Replace the servo board if the error cannot be resolved.
3. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
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3. Troubleshooting
Error code
: D0009
Error message : [Servo boardXX]CPU exception. (PC=XX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
This error occurs at the same time as when [Servo board] CPU error (D0007) or [Servo boardXX]
Floating point exception (D0008) occurs.
Main cause:
Defect in the servo board.
Countermeasure:
1. Refer to countermeasures for D0007 or D0008 which is occurring at the same time as this
error.
2. Inform KHI which error is occurring, D0007 Servo board] CPU error or D0008 [Servo
boardXX] Floating point exception, and of the value of PC.
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3. Troubleshooting
Error code
: D0900
Error message : Teach data is broken.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The data base (link list) information controlling teach data in user memory is damaged (after
accessing teach data in the editor, for example).
Main cause:
1. Defective file system in the CF card.
2. Defect in the main CPU board.
3. Defect in the power sequence board.
4. Defect in the AVR.
Countermeasures:
1. Promptly turn ON the DIP SW-8 on the main CPU board when this error occurs. Then,
execute initialization and reload the teach data.
[NOTE]
The system memory cannot be completely initialized by
SYSINT command or Aux. function 0805 Initialize System
since a part of the system data is maintained.
2. Replace the CF card if the error recurs.
3. Replace the main CPU board if the error recurs.
4. Replace the power sequence board if the error recurs.
5. Replace the AVR if the error recurs.
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3. Troubleshooting
Error code
: D0904
Error message : Memory is locked due to AC_FAIL.
Error processing : Display
Error reset : Non-acceptable
Content:
This error occurs when the external power supply decreases and saving or loading are executed
after power supply abnormality (AC FAIL) is detected in the AVR.
Countermeasure:
This error may occur when the controller power is turned OFF. This error can be fixed by
turning the controller power ON again. If the error is still not fixed, check for any abnormalities
in items relating to the power supply circuit including the AVR, or replace the power sequence
board.
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3. Troubleshooting
Error code
: D1021
Error message : Servo FPGA configuration data not found.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Configuration data in servo FPGA software (armsf.cnf) cannot be read properly.
Main cause:
Servo FPGA configuration data whose name is arms.cnf does not exist in the CF card on the main
CPU board.
Countermeasure:
1. Check the version of servo group software, and reinstall the servo group software.
2. Replace the CF card on the main CPU board.
3. Replace the main CPU board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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3. Troubleshooting
Error code
: D1025
Error message : [Servo boardXX]Detected Watch dog error.(Servo FPGA)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The bus access from the CPU on the servo board to the servo FPGA stopped for a certain period
of time.
Main cause:
Defect in the servo board.
Countermeasure:
1. Turn the controller power OFF and then ON, and check if the same error occurs.
2. Replace the servo board if the same error occurs.
3. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1026
Error message : [Servo boardXX]Abnormal signal input from power sequence board.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
When the power sequence board detects AC primary power supply failure for AVR for control
power, DC power supply failure, or abnormal watch dog in main CPU board, it transmits the
error signals to the servo board, and the servo board detects the abnormalities.
Main cause:
1. Defective wiring between the mother board and servo board.
2. Defect in the power sequence board.
3. Defect in the servo board.
4. Defect in the mother board.
5. Defect in the main CPU board.
Countermeasure:
1. Check the wiring between the mother board (X206) and servo board (X502).
2. Replace the power sequence board.
3. Replace the servo board.
4. Replace the mother board.
5. Replace the main CPU board.
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Error code
: D1027
Error message : [MCXX]Detected Watch dog error.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The bus access from CPU to CPLD has stopped for a certain period of time in the MC control
board.
Main cause:
Defect in the MC control board.
Countermeasure:
1. Turn the controller power OFF and then ON.
2. If the same error occurs, replace the MC control board.
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Error code
: D1028
Error message : [Servo boardXX]DC power is abnormal.(Servo FPGA)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Each DC power supply voltage deviated from the rated value in the servo board.
Main cause:
1. Inappropriate voltage adjustment for the AVR for control power.
2. Defect in the AVR for control power.
3. Defect in the servo board.
Countermeasure:
1. Check the 5 V between test pins on the power sequence board, then adjust the voltage so that it
becomes within 5.05 – 5.15 V.
2. Replace the AVR.
3. Replace the servo board.
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Error code
: D1029
Error message : [Servo boardXX]AC primary power is abnormal.(Servo FPGA)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An abnormal state occurred in the AC primary power supply of the slave controller.
Main cause:
1. Abnormal AC primary power supply of the slave controller.
2. Defective AVR in the slave controller.
3. Defect in the servo board.
4. Disconnection of the signal harness between the mother board and servo board in the slave
controller.
Countermeasure:
1. Turn the slave controller power OFF and then ON.
2. Replace the AVR of the slave controller.
3. Replace the servo board.
4. Check the connection of the signal harness between the mother board and servo board in the
slave controller.
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Error code
: D1030
Error message : Cannot start communication with the servo boardXX.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Communication with the servo board cannot be started at controller power ON.
Main cause:
1. Unconnected servo board, or disconnection of the harness between the main CPU board and
servo board.
2. Defect in the servo board.
3. Defect in the main CPU board.
4. Defect in the mother board.
Countermeasure:
1. Check the connection with the servo board.
2. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, servo board and mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1031
Error message : Read error of servo software.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Failed in reading servo software(armsv.mb).
Main cause:
1. Servo group software is not installed correctly.
2. Defective CF card in the main CPU board.
3. Defect in the main CPU board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Replace the CF card of the main CPU board.
3. Replace the main CPU board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1032
Error message : [Servo boardXX]Download error of servo software.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Servo software was not downloaded correctly at controller power ON.
Main cause:
1. Servo group software is not installed correctly.
2. Defective CF card in the main CPU board.
3. Defect in the servo board.
4. Defect in the main CPU board.
5. Defect in the mother board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Replace the CF card of the main CPU board.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, the servo board, or the mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1033
Error message : Connection Port No(XX) and Servo board No(XX) mismatch.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Communication port channel for the servo board on the main CPU board does not correspond to
the rotary switch number set on the servo board.
Main cause:
1. Incorrect setting on the rotary switch (SW7) on the servo board.
2. Defective wiring when two or more servo boards are used.
3. Defect in the servo board.
4. Defect in the main CPU board.
5. Defect in the additional servo communication board on the main CPU board.
Countermeasure:
1. Check the setting on the rotary switch in the servo board. (In proper setting, “0” is set when one
servo board is used. When two or more boards are used, number is set from “0” for the first
board, “1” for the second board, and so on.)
2. Check the each harness state from the main CPU board or additional servo communication
board.
3. Replace the servo board.
4. Replace the main CPU board.
5. Replace the additional servo communication board.
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Error code
: D1034
Error message : The servo data file is missing or not acceptable.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
This error occurs when servo data file for the specified arm model was not found when turning
ON the controller power. When the servo software does not contain the data of the arm model,
code 101 is displayed.
Main cause:
1. Improper servo software version.
2. Servo group software is not installed properly.
3. Defect in the CF card of the main CPU board.
4. Defect in the servo board.
5. Defect in the main CPU board.
6. Defect in the mother board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Replace the CF card in the main CPU board.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, servo board or mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1035
Error message : [Servo boardXX]Init. error of servo software.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Failed in initialization of servo software at controller power ON.
Main cause:
1. The servo group software is not installed correctly.
2. The servo group software which is incompatible with the AS group software is installed.
3. Defect in the servo board.
4. Defect in the main CPU board.
5. Defect in the mother board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Install servo group software which is compatible with the AS group software.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, the servo board, or the mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1036
Error message : [Servo boardXX]Download error of servo data.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Failed in download of servo data at controller power ON.
Main cause:
1. Servo group software is not installed correctly.
2. Defect in the CF card of the main CPU board.
3. Defect in the servo board.
4. Defect in the main CPU board.
5. Defect in the mother board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Replace the CF card of the main CPU board.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, the servo board, or the mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1037
Error message : [Servo boardXX]Configuration error in servo FPGA.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Error occurred during processing the servo FPGA configuration data (armsf.cnf).
Main cause:
1. Servo group software was not installed properly.
2. Defective CF card on the main CPU board.
3. Defect in the servo board.
4. Defect in the main CPU board.
5. Defect in the mother board.
Countermeasure:
1. Check the version of servo group software, and reinstall the servo group software.
2. Replace the CF card on the main CPU board.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, servo board, or mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1038
Error message : [Servo boardXX]Upload error of servo software initial data.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
An error occurred while processing initialization data upload in the servo board at controller
power ON.
Main cause:
1. Servo group software is not installed correctly.
2. Servo group software is incompatible with the AS group software.
3. Defect in the servo board.
4. Defect in the main CPU board.
5. Defect in the mother board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Install servo group software which is compatible with the AS group software.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, the servo board, or the mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1039
Error message : [Servo boardXX] Download error of servo software initial data.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
An error occurred while processing initialization data download in the servo board at controller
power ON.
Main cause:
1. Servo group software is not installed correctly.
2. Servo group software is incompatible with the AS group software.
3. Defect in the servo board.
4. Defect in the main CPU board.
5. Defect in the mother board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Install servo group software which is compatible with the AS group software.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, the servo board, or the mother board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1040
Error message : [Servo boardXX]Device check error. (CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
An error was detected when checking the memory device on the servo board.
Main cause:
Defect in the servo board.
Countermeasure:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2 If reproducibility cannot be confirmed or the program does not return to normal, replace the
servo board.
3. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D1041
Error message : JtXX axis brake release circuit is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
If motor power is supplied when the brake release circuit is defective in the MC control board,
brake is released before servo control starts.
Main cause:
Defect in the brake release circuit in the MC control board.
Countermeasure:
Replace the MC control board.
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Error code
: D1500
Error message : Encoder misread error JtXX.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
When the encoder data is read immediately after the controller power is turned ON, stable
data could not be read. This is detected by the servo software.
Encoder
Encoder
Servo board
Encoder
I/F
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Controller
Robot main body
Main cause:
1. Disconnection or short-circuit in the encoder harness.
2. Defect in the encoder.
3. Defect in the servo board.
Countermeasure:
1. Check for disconnection or short-circuit in the encoder harness, and replace the encoder.
2. Replace the servo board.
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Error code
: D1502
Error message : Amp overcurrent JtXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
During servoing, the feedback current from the current detection circuit on the power block
exceeds 1.5 times of the maximum instantaneous current limit to the motor.
A current threshold value for each joint is set into and detected by the servo FPGA mounted on
the servo board.
Servo FPGA
Current feedback
Servo board
PWM
Current
detection
circuit
IPM
Each motor
Robot main body
Power block
Controller
Main cause:
1. Defect in the power block.
2. Defect in the servo board.
3. U, V, or W-phase and the ground line are short-circuited between the power block and the
motor.
4. Defect in the motor.
Countermeasure:
1. Replace the servo amplifier unit.
2. Check the connection of U, V, or W-phase and the ground line between the power block and
the motor, and replace the separate harness/machine harness if necessary.
3. Replace the motor.
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Error code
: D1504
Error message : Abn. curr feedback JtXX. (Amp fail, pwr harness disconnect)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
In the period from servo ON to brake release, the feedback current is almost 0 despite the current
command is constantly sent.
1GM board
Servo
FPGA
I/V
converter
Servo
CPU
Current
feedback
1KBboard
board
Servo
Current
Current
detection
sensor
circuit
IPM
U, V, W
earth
Each
m otor
Robot m ain body
Power block
Controller
Main cause:
1. U-phase, V-phase or W-phase of the motor power line is disconnected. (Normally,
disconnection is not checked.)
2. Defective connection in the power line for controller harness, separate harness or machine
harness.
3. Defect in the power block.
Countermeasure:
1. Check for defective wiring or disconnection, and replace the harness if necessary.
2. Replace the servo amplifier unit.
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Error code
: D1512
Error message : Brake line error for JtXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The CPU on the MC control board detected error signals from MOSFET for brake release.
Robot
main body
Motor
Motor brake line
Controller
MC power board
Brake power supply
Transformer
Protector
DC26V
Safety circuit
Brake power supply error signal
CPU
Voltage detect.
Brake release signal
MOSFET
Brake line error signal
MC control board
Servo board
Timing for detecting brake line error
The brake line error is detected at the time shown below. This error is not detected at motor
power OFF.
Safety relay for
motor power ON
(KS1, KS2)
ON
Start
Servo control
Release
Brake release
Disconnection
detection
Short-circuit
detection
The error cause depends on the timing of the error occurrence: if the error occurs before servo
control starts, the cause may be a disconnection, and if after servo control starts, the cause may be
a short-circuit. During automatic operation, disconnection is not detected.
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Main cause:
1. Short-circuit, disconnection or ground fault (contact with earth) of the motor brake line.
2. Defect in the MC control board.
3. Attempted to turn ON motor power and operate robot while pressing the brake release switch.
Countermeasure:
1. Check for disconnection or short-circuit in the motor harness.
2. Check for wiring failure or disconnection in the motor harness.
3. Replace the MC control board.
4. Do not press the brake release switch when attempting to operate robot.
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Error code
: D1516
Error message : Mismatch betw hard/software settings for HOLD backup time.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The settings that cut OFF the motor power of hardware in 2 seconds after switching HOLD/RUN
from RUN to HOLD does not match between software and hardware.
Main cause:
1. Although 2 sec. of backup time is set in the software, no backup time is set in the
hardware.
2. Although no backup time is set in the software, 2 sec. of backup time is set in the
hardware.
3. Defect in the power sequence board.
Countermeasure:
1. To set 2 sec. of backup time, set SW2-2 on the power sequence board to ON, then set
[Hold Backup Time] to [Standard] in Aux. 2021-2.
2. To set no backup time, set SW2-2 on the power sequence board to OFF, then set [Hold
Backup Time] to [OFF] in Aux. 2021-2.
3. Replace the power sequence board.
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Error code
: D1517
Error message : Blown fuse on safety circuit emergency line.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Blown fuse on Emergency Stop line. (Fuse F1 on the upper side of the power sequence board.)
Main cause:
1. Defective wiring for Emergency Stop, safety fence, external trigger, etc.
2. Short-circuit or ground fault in other safety circuit harnesses (for Emergency Stop line, limit
switch, or teach pendant).
3. Defect in the power sequence board.
Countermeasure:
1. Check for the defective wirings for Emergency Stop, safety fence, external trigger, etc., and
correct the wiring if defective.
2. Replace the defective harness.
3. Replace the power sequence board.
！
CAUTION
Before wiring safety circuits, be sure to turn the controller
power OFF. Doing the wiring at controller power ON, the
Emergency Stop line fuse may blow when the lines touch the
chassis.
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Error code
: D1518
Error message : Mismatch in the Emer. Stop condition on safety circuit.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Contacts state for Emergency Stop switches on operation panel, teach pendant and external panel
does not match between the first and second safety circuits.
Main cause:
1. Defective circuit or wiring for External Emergency Stop input, or only single circuit connected.
2. Disconnection or ground fault in the wiring of Emergency Stop line.
3. Defective Emergency Stop switch in the operation panel or teach pendant.
4. Defect in the power sequence board.
5. Defect in the mother board.
Countermeasure:
1. Check the circuit and wiring for the External Emergency Stop switch(es), and correct it if
defective.
2. Press each E-STOP so that the defective switch can be identified.
3. Replace the defective E-STOP switch in the operation panel or teach pendant, or its harness if
defective.
4. Replace the power sequence board.
5. Replace the mother board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
！
CAUTION
Before wiring safety circuits, be sure to turn the controller power
OFF. Doing the wiring at controller power ON, the Emergency
Stop line fuse may blow when the lines touch the chassis.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both
first and second circuits. When they are ON, error reset cannot be executed.
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Error code
: D1520
Error message : Mismatch in safety circuit TEACH/REPEAT condition.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Contacts state for TEACH/REPEAT switch does not match between the first and second safety
circuits.
Main cause:
1. Defect in the TEACH/REPEAT switch.
2. Disconnection, etc. between the mother board and TEACH/REPEAT switch.
3. Defect in the power sequence board.
4. Defect in the mother board.
Countermeasure:
1. Replace the TEACH/REPEAT switch.
2. Check the wiring between the mother board and TEACH/REPEAT switch.
3. Replace the power sequence board.
4. Replace the mother board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both
first and second circuits. When they are ON, error reset cannot be executed.
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Error code
: D1521
Error message : Mismatch in safety circuit safety-fence condition.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Contacts state for safety fence does not match between the first and second safety circuits.
Main cause:
1. Defective circuit or wiring in safety fence input. Or only the first circuit is input.
2. Disconnection or ground fault in wiring of safety fence input.
3. Defective safety fence switch.
4. Defect in the power sequence board.
Countermeasure:
1. Check the circuit and wiring in the safety fence input and modify it if necessary.
2. Replace the switch.
3. Replace the power sequence board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
！
CAUTION
Before wiring safety circuits, be sure to turn the controller power
OFF. Doing the wiring at controller power ON, the Emergency
Stop line fuse may blow when the lines touch the chassis.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both first
and second circuits. When they are ON, error reset cannot be executed.
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Error code
: D1522
Error message : Mismatch in cond. of safety circuit enabling device.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Contacts state for teach trigger switch of the teach pendant does not match between the first and
second safety circuits.
Main cause:
1. Disconnection, short-circuit, ground fault, etc. in the wiring of teach trigger switch.
2. Defect in the teach trigger switch.
3. Defect in the power sequence board.
4. Defect in the mother board.
Countermeasure:
1. Check the teach pendant harness or controller harness.
2. Replace the teach pendant.
3. Replace the power sequence board.
4. Replace the mother board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. Two contacts are built into the teach trigger switches. If the trigger switch is not
pressed firmly enough, only one contact may become ON, which may result in this
error. Also, in the 3-position trigger switches, pressing them too firmly may cause
trigger OFF. In these cases, lose hold of the swtich and try to press the switch again.
2. This error does not occur when single circuit is set for safety circuit.
3. Error reset is possible only when the safety circuits are OFF state(open state) in both
first and second circuits. When they are ON, error reset cannot be executed.
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Error code
: D1523
Error message : Mismatch in cond. of safety circuit ext. enabling device.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Contacts state for external trigger switches does not match between the first and second safety
circuits.
Main cause:
1. Disconnection, short-circuit, ground fault, etc. in the wiring of external trigger.
2. Defect in the external trigger switch.
3. Defect in the power sequence board.
Countermeasure:
1. Check the circuit and wiring in the external trigger, and modify it if necessary.
2. Replace the external trigger switch.
3. Replace the power sequence board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
！
CAUTION
Before wiring safety circuits, be sure to turn the controller power
OFF. Doing the wiring at controller power ON, the Emergency
Stop line fuse may blow when the lines touch the chassis.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both first
and second circuits. When they are ON, error reset cannot be executed.
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Error code
: D1529
Error message : Signal harness disconnected or Encoder power error.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Communication error occurred in the encoders of all axes.
Main cause:
1. Disconnection, short-circuit, or no connection in the separate (signal) harness, or machine
harness.
2. Disconnection, or short-circuit, etc. in the 12 V wiring in the controller.
3. Abnormal encoder battery backup board.
Countermeasure:
1. Check the connection of the separate (signal) harness, or machine harness.
2. Check the 12 V wiring in the controller.
3. Replace the encoder battery backup board.
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Error code
: D1543
Error message : [Servo boardXX]DC 5V is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The 5 V supplied to the servo board from the AVR for control power deviated from the rated
value.
Main cause:
1. Inappropriate voltage adjustment for the AVR for control power.
2. Defect in the AVR for control power.
3. Defect in the servo board.
4. Defect in the power block board.
5. Defect in the MC unit (MC control board).
6. Ground fault or short-circuit in the 5 V wiring.
Countermeasure:
1. Check the 5 V between test pins on the power sequence board, then adjust the voltage so that it
becomes within 5.05 – 5.15 V.
2. Replace the AVR.
3. Replace the servo board.
4. Replace the servo amplifier unit.
5. Replace the MC control board.
6. Check for the ground fault or short-circuit in the 5 V wiring.
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Error code
: D1544
Error message : [Servo boardXX]DC 3.3V is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The 3.3 V deviated from the rated value in the servo board.
Main cause:
Defect in the servo board.
Countermeasure:
Replace the servo board.
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Error code
: D1545
Error message : [Servo boardXX]DC 12V is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The 12 V supplied to the servo board from the AVR for control power deviated from the rated
value.
Main cause:
1. Defect in the AVR for control power.
2. Ground fault or short-circuit in the 12 V wiring.
3. Defect in the servo board.
4. Defect in the power block board.
5. Defect in the MC unit (MC control board).
6. Defect in the mother board.
Countermeasure:
1. Replace the AVR.
2. Check for the ground fault or short-circuit in the 12 V wiring.
3. Replace the servo board.
4. Replace the servo amplifier unit.
5. Replace the MC control board.
6. Replace the mother board.
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Error code
: D1546
Error message : [Servo boardXX]DC 2.5V is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The 2.5 V deviated from the rated value in the servo board.
Main cause:
Defect in the servo board.
Countermeasure:
Replace the servo board.
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Error code
: D1547
Error message : [Servo boardXX]DC 1.2V is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The 1.2 V deviated from the rated value in the servo board.
Main cause:
Defect in the servo board.
Countermeasure:
Replace the servo board.
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Error code
: D1548
Error message : [Servo boardXX]DC 1.0V is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The 1.0 V deviated from the rated value in the servo board.
Main cause:
Defect in the servo board.
Countermeasure:
Replace the servo board.
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Error code
: D1549
Error message : [Servo boardXX]Primary power source is too low.
Error processing : Motor power OFF
Error reset : Non-acceptable
The AC primary power supply voltage has become less than –20% of the rated value and the state
continues for 1 - 2 sec. in the slave controller.
Main cause:
1. Abnormal AC primary power supply in the slave controller.
2. Defective AVR in the slave controller.
3. Disconnection of the signal harness between the mother board and servo board in the slave
controller.
4. Defect in the servo board.
Countermeasure:
1. Turn the slave controller power OFF and then ON.
2. Replace the AVR of the slave controller.
3. Check the connection of the signal harness between the mother board and servo board in the
slave controller.
4. Replace the servo board.
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Error code
: D1550
Error message : [Servo boardXX]Primary power source is too high.
Error processing : Motor power OFF
Error reset : Non-acceptable
The AC primary power supply voltage has become -20% or more of the rated value and the state
continues for 1 - 2 sec. in the slave controller.
Main cause:
1. Abnormal AC primary power supply in the slave controller.
2. Defective AVR in the slave controller.
3. Disconnection of the signal harness between the mother board and servo board in the slave
controller.
4. Defect in the servo board.
Countermeasure:
1. Turn the slave controller power OFF and then ON.
2. Replace the AVR of the slave controller.
3. Check the connection of the signal harness between the mother board and servo board in the
slave controller.
4. Replace the servo board.
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Error code
: D1551
Error message : [Servo boardXX]AC primary power OFF.
Error processing : Motor power OFF
Error reset : Non-acceptable
The AC primary power supply voltage has become less than -30% of the rated value and the state
continues for 1/50 - 1/30 sec. in the slave controller.
Main cause:
1. Abnormal AC primary power supply in the slave controller.
2. Defective AVR in the slave controller.
3. Disconnection of the signal harness between the mother board and servo board in the slave
controller.
4. Defect in the servo board.
Countermeasure:
1. Turn the slave controller power OFF and then ON.
2. Replace the AVR of the slave controller.
3. Check the connection of the signal harness between the mother board and servo board in the
slave controller.
4. Replace the servo board.
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Error code
: D1552
Error message : [MCXX]DC 3.3V is abnormal.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The power supply detection circuit for 3.3 V detected the value which deviated from the rated
value in the MC control board.
Main cause:
1. Defect in the MC control board.
2. Defect in the 3.3 V system (wiring, MC power board) in the MC unit.
Countermeasure:
1. Replace the MC control board.
2. Replace the MC unit.
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Error code
: D1553
Error message : [MCXX]DC 5V is abnormal.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The power supply detection circuit for 5 V detected the value which deviated from the rated value
in the MC control board.
Main cause:
1. Inappropriate voltage adjustment for the AVR for control power.
2. Defect in the AVR for control power.
3. Defect in the MC control board.
4. Ground fault or short-circuit in the 5 V wiring.
Countermeasure:
1. Check the 5 V between test pins on the power sequence board, then adjust the voltage so that it
becomes within 5.05 – 5.15 V.
2. Replace the AVR.
3. Replace the MC control board.
4. Check for the ground fault or short-circuit in the 5 V wiring.
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Error code
: D1557
Error message : [Power sequence board]DC 3.3V is abnormal.
Error processing : Controller power OFF
Error reset : Non-acceptable
Content:
The 3.3 V supplied to the power sequence board from the AVR for control power deviated from
the rated value.
Main cause:
1. Inappropriate voltage adjustment for the AVR for control power.
2. Defect in the AVR for control power.
3. Defect in the power sequence board.
Countermeasure:
1. Check the 3.3 V between test pins on the power sequence board, then adjust the voltage so that
it becomes within 3.25 – 3.35 V.
2. Replace the AVR.
3. Replace the power sequence board.
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Error code
: D1558
Error message : [Power sequence board]DC 5V is abnormal.
Error processing : Controller power OFF
Error reset : Non-acceptable
Content:
The 5 V supplied to the power sequence board from the AVR for control power deviated from the
rated value.
Main cause:
1. Inappropriate voltage adjustment for the AVR for control power.
2. Defect in the AVR for control power.
3. Defect in the power sequence board.
Countermeasure:
1. Check the 5 V between test pins on the power sequence board, then adjust the voltage so that it
becomes within 5.05 – 5.15 V.
2. Replace the AVR.
3. Replace the power sequence board.
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Error code
: D1559
Error message : [Power sequence board]DC 12V is abnormal.
Error processing : Controller power OFF
Error reset : Non-acceptable
Content:
The 12 V supplied to the power sequence board from the AVR for control power deviated from
the rated value.
Main cause:
1. Defect in the AVR for control power.
2. Defect in the power sequence board.
3. Ground fault or short-circuit in the 12 V wiring.
Countermeasure:
1. Replace the AVR.
2. Replace the power sequence board.
3. Check for the ground fault or short-circuit in the 12 V wiring.
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Error code
: D1560
Error message : [Power sequence board]DC 24V is abnormal.
Error processing : Controller power OFF
Error reset : Acceptable
Content:
The DC24 V power supplied to the power sequence board from the AVR for control power
deviated from the rated value.
Main cause:
1. Controller power was turned OFF by using external remote OFF.
2. Defect in the AVR for control power.
3. Defect in the power sequence board.
4. The 24 V was ground-faulted or short-circuited in the controller wiring.
Countermeasure:
1. Check if the controller power was turned OFF by using external remote.
2. Replace the AVR.
3. Replace the power sequence board.
4. Check for ground fault or short-circuit in the 24 V controller wiring.
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Error code
: D1561
Error message : [Power sequence board]AC primary power OFF.
Error processing : Controller power OFF
Error reset : Acceptable
Content:
This error occurs when AC primary power voltage is less than –30% of the rated value and the
state continues for 1/50 to 1/30 sec.
External
power supply
AC200 V
NFB
AVR for
control power
REMOTE
AC error signal
AVR
output cut
Main CPU
board
CPLD
Power sequence board
Main cause:
1. Abnormal AC primary power supply.
2. Defective wiring or connector connection in the controller.
3. Defect in the AVR.
4. Defect in the power sequence board.
Countermeasure:
1. Check the primary power supply voltage.
2. Check the wiring or connector connection in the controller.
3. Replace the AVR.
4. Replace the power sequence board.
[NOTE]
The error occurrence after turning OFF the controller power switch is not abnormal state.
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Error code
: D1562
Error message : [Power sequence board]AC primary power voltage is too high.
Error processing : Controller power OFF
Error reset : Acceptable
Content:
This error occurs when AC primary power voltage became +20% or more of the rated value and
the state continues for 1 to 2 sec.
External
power supply
AC200 V
NFB
AVR for
control power
REMOTE
AC error signal
AVR
output cut
Main CPU
board
CPLD
Power sequence board
Main cause:
1. Abnormal AC primary power supply.
2. Defective wiring or connector connection in the controller.
3. Defect in the AVR.
4. Defect in the power sequence board.
Countermeasure:
1. Check the primary power supply voltage.
2. Check the wiring or connector connection in the controller.
3. Replace the AVR.
4. Replace the power sequence board.
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Error code
: D1563
Error message : [Power sequence board]AC primary power voltage is too low.
Error processing : Controller power OFF
Error reset : Acceptable
Content:
This error occurs when AC primary power voltage became less than -20% of the rated value and
the state continues for 1 to 2 sec.
External
power supply
AC200 V
NFB
AVR for
control power
REMOTE
AC error signal
AVR
output cut
Main CPU
board
CPLD
Power sequence board
Main cause:
1. Abnormal AC primary power supply.
2. Defective wiring or connector connection in the controller.
3. Defect in the AVR.
4. Defect in the power sequence board.
Countermeasure:
1. Check the primary power supply voltage.
2. Check the wiring or connector connection in the controller.
3. Replace the AVR.
4. Replace the power sequence board.
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Error code
: D1564
Error message : [Power sequence board]Remote power off signal was detected.
Error processing : Controller power OFF
Error reset : Non-acceptable
Content:
Remote power supply OFF signal was input in the power sequence board.
Main cause:
1. Remote power supply OFF signal was input, which is not normally input in the AS software.
In case of the error occurrence when using software exchange function from the AS software,
it is not actually an error.
2. Defect in the main CPU board.
Countermeasure:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. The problem is likely to be in the AS system if this error occurs only when a certain step of a
program or a special operation are executed. In this case, report all details to KHI, including
information of all messages, robot model, controller model, machine number, AS/servo
software versions, operation at the time of error occurrence, the contents of program lists,
equipped options, etc.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board.
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Error code
: D1565
Error message : Cannot access power sequence board.(CodeXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An error occurred when accessing to the power sequence board.
Main cause:
Defect in the main CPU board.
Countermeasure:
1. Reset the error. If it cannot be reset, turn the controller power OFF and then ON. If a
message for initialization appears, select <NO>.
2. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board.
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Error code
: D1566
Error message : P-N capacitor has not discharged.(Servo boardXX)(MCXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
When the controller power is ON, the P-N voltage detection circuit detected 60 V or more.
Main cause:
1. Defect in the MC power board.
2. Disconnection or defective connection in the harness between the MC unit and regenerative
resistor.
3. Defect in the MC control board.
4. Disconnection or defective connection in the harness between the MC control board and MC
power board.
Countermeasure:
1. Replace the MC unit.
2. Check for unconnected connector or disconnection of the harness between the MC unit (X353)
and regenerative resistor (XRS).
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Error code
: D1567
Error message : [Servo boardXX]Primary Power source is error.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Abnormal voltage of AC primary power supply is detected instantaneously in the slave controller,
but the code from the AVR could not be read normally.
Main cause:
1. Abnormal AC primary power supply in the slave controller.
2. Defective AVR in the slave controller.
3. Disconnection of the signal harness between the mother board and servo board in the slave
controller.
4. Defect in the servo board.
Countermeasure:
1. Turn the slave controller power OFF and then ON.
2. Replace the AVR of the slave controller.
3. Check the connection of the signal harness between the mother board and servo board in the
slave controller.
4. Replace the servo board.
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Error code
: D1568
Error message : [Servo boardXX]Power supply circuit for PWM signal output malfunctioned.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An abnormality is found in the PWM power supply output circuit on the servo board.
Main cause:
1. Defect in the servo board.
2. Defect in the power block board.
Countermeasure:
1. Replace the servo board.
2. Replace the servo amplifier unit.
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Error code
: D2055
Error message : [Power sequence board]Watchdog error was detected.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The bus access from the main CPU board to the power sequence board was not made for a certain
period of time (16 ms) or more.
Main cause:
1. Defect in the main CPU board.
2. Defect in the power sequence board.
3. Defect in the mother board.
Countermeasure:
1. Turn the AC primary power OFF and then ON, and check if the same error occurs.
2. Replace the main CPU board.
3. Replace the power sequence board.
4. Replace the mother board.
5. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D2056
Error message : [I/O board(No.XX)]Several boards have same ID address.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The same address is set in two or more IO boards.
Main cause:
1. Incorrect setting in the DIP switch (SW1) for setting address in the IO board.
2. Defect in the IO board.
Countermeasure:
1. Check the DIP switch (SW1) setting in the IO board.
2. Replace the IO board.
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Error code
: D2057
Error message : [Servo boardXX]No response from Servo FPGA device.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
No regular response is received from the servo FPGA software in the servo board.
Main cause:
Defect in the servo board.
Countermeasure:
1. Check if the correct servo FPGA software (ARMSF) is downloaded to the servo board
(Software version check).
2. Replace the servo board.
3. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: D2058
Error message : [Main CPU board]DC power supply is abnormal.(XX mV)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Power supply voltage is abnormal in any one of the power supplies including those generated in
the main CPU board.
Main cause:
1. Abnormal main CPU board.
2. Abnormal AVR.
Countermeasure:
At first, turn the controller power OFF and then ON. If the error still occurs:
1. Replace the main CPU board.
2. Replace the AVR.
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Error code
: D2068
Error message : [IO board No. XX]Device check failure.(CodeXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The boot process for the IO board failed after turning ON the controller power due to the causes
excluding the following errors:
E1009 No.XX I/O board is not installed.
D2056 [I/O board(No.XX)]Several boards have same ID address.
Main cause:
1. AS group software is not installed correctly.
2. Defect in the CF card of the main CPU board.
3. Defect in the main CPU board.
Countermeasure:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the CF
card, or main CPU board.
4. Reinstall the AS group software.
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Error code
: D2069
Error message : [ANYBUS interface board(No.XX)]Several boards have the same ID address.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The same address was set in two or more ANYBUS interface boards.
Main cause:
1. Incorrect setting in the DIP switch (SW1) for setting address in the ANYBUS interface board.
2. Defect in the ANYBUS interface board.
Countermeasure:
1. Check the DIP switch (SW1) setting in the ANYBUS interface board.
2. Replace the ANYBUS interface board.
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Error code
: E0002
Error message : [Servo boardXX]CPU BUS error.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The bus access from the CPU on the servo board is abnormal.
Main cause:
Defect in the servo board.
Countermeasure:
1. Turn the AC primary power OFF and then ON, and check if the same error occurs.
2. Replace the servo board.
3. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: E0903
Error message : Check sum error of system data.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The check sum data for the AS software system data (machine model, number of axes, option
setting, etc.) has been rewritten for some reason.
Main cause:
1. Defect in the CF card.
2. Defect in the main CPU board.
The error occurrence is not abnormal when files with system or robot data (model, options, etc.)
have been loaded and data settings have been changed at AS software replacement, etc.
Countermeasures:
1. Set “Enable” in Aux. function 0803 Reset Check Sum Error, and reset the error. This setting
is automatically reset to “Disable” when turning OFF → ON the controller power again.
2. If the step 1 above does not solve the error, the instruction for faulty data will be displayed.
Modify the data first and then fix errors by Aux. function 0803 Reset Check Sum Error again.
3. When the error cannot be fixed or the same error occurs other than the causes above, replace
the main CPU board or CF card.
[NOTE]
An initial listing of set values is enclosed with the controller of each machine or
with the manuals at factory shipment. Confirm the value settings with this list.
Keep this list for future use. When changing any setting, record the new
values. (E.g.: changing of options, operating range settings, etc.)
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Error code
: E1009
Error message : No. XX I/O board is not installed.
Error processing : Display
Error reset : Acceptable
Content:
The first address of the IO board, etc. based on the IO signal numbers set in Aux. function 0611
Number of IO Signals cannot be read at controller power ON. This error typically occurs in the
following condition.
Number of IO signals set in Aux. function 0611 > Number of mounted IO boards × 32
However, when the sequencer board is used, this error does not occur. Also, INT (Number of
Internal Signals) in Aux. function 0611 is a virtual signal of memory and is not related to the IO
board.
Main cause:
1. Incorrect setting in Aux. function 0611 Number of IO Signals.
2. IO board, etc. is not mounted.
3. Incorrect address settings on DIP switch(SW1) for a board address in the IO board.
4. Defect in the IO board.
Countermeasure:
1. Set the correct number of signals in Aux. function 0611 Number of IO Signals.
2. Correctly set the DIP switch (SW1) for a board address in the IO board and then mount it in the
card rack. IO board(s) is usually mounted in the vacant slots starting from the leftmost, but
the board works properly wherever it is mounted.
[NOTE]
1. After resetting this error, automatic operation is possible without the IO board.
In this case, the input is fixed to OFF, but the output can be switched between
ON and OFF in the AS software as a normal operation.
2. Maximum number of signals which can be set in Aux. function 0611 Number
of IO Signals is 960 for DO and DI, and 960 for INT. However, the number
of signals for DO and DI is restricted by hardware or other options. Usually,
the number of signals can be increased/decreased in units of 32 by
mounting/dismounting IO board, etc.
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Error code
: E1028
Error message : JtXX motor overloaded.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The feedback current from the power block has exceeded the continuous current rating of the
motor longer than the time allowed. The servo software detects this error based on the following
data (overload curve).
Servo board
Motor current
Servo
FPGA
Servo
CPU
Abnormal
Current
feedback
Continuous
rating current
Time
Overload curve
IPM
Current
detection
circuit
U,V,W earth
Each
motor
Robot main body
Power block
Main cause:
1. Mechanical factors:
(1) The robot arm comes in contact with the jig, etc.
(2) The cables etc. are caught by the robot arm.
(3) Defective reducer, gear, bearing, etc.
(4) Too small backlash in the gear reduction part.
(5) The payload exceeds robot rated weight.
(6) A robot motion pattern repeated which results in exceeding the rated motor capacity (due to
shuttle movement, etc.).
(7) The motor brake is not released.
2. Electric factors:
(1) Disconnection of the motor power line of U, V, or W phases. (No disconnection check is
performed.)
(2) The motor brake is not released.
(3) Defect in the power block.
(4) Defect in the servo board.
(5) Defect in the motor.
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Countermeasure:
1. If the robot arm interfered with something, move it away from the interference in teach mode.
Then, check for defects in the drive parts, reducers, etc., and for positioning deviation caused
by arm deformation.
2. When any parts (reducers, etc.) are damaged, check and replace them if necessary.
3. If the payload or the motion pattern causes the error, modify them.
4. When an electrical factor causes the error, check the servo amp. unit, MC unit, motor, etc., and
replace them if necessary.
[NOTE]
Repeating this error may burn out the motor. Be sure to
remove the causes before restarting the robot.
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Error code
: E1029
Error message : Encoder rotation data is abnormal. (JtXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Encoder detected a difference of one or more rotations between the data of number of rotations
obtained by counting the magnetic pulses and the number of encoder rotations obtained by
converting encoder value change to encoder rotations.
Encoder
Servo
CPU
Encoder
Encoder
I/F
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. Defect in the encoder.
2. Defect in the servo board.
Countermeasure:
1. Replace the encoder.
2. Replace the servo board.
[NOTE]
This error may occur immediately after error occurrences of E1035,
E1036 and E1037 due to a discrepancy between the encoder value and
the current value in the servo software.
When this error occurs, the discrepancy of encoder value is in
multiples of 8192, which is the value of one rotation.
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Error code
: E1030
Error message : Encoder data is abnormal. (JtXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The difference between encoder values right before turning OFF the controller power and at the
next controller power ON exceeds the value set in Aux. function 0504 Encoder Value Error
Range at Power-ON. This is detected by the AS software.
This value is usually set to 2.0 degrees for each rotation axis. When set as 0.0 degrees, this error
is not detected. Setting too small value may cause this error when turning ON the controller
power, even though there is no abnormality.
Encoder
Servo
CPU
Encoder
Encoder
I/F
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
[NOTE]
The error occurrence right after executing initialization does
not mean abnormality. Because at initialization, the last
encoder value right before turning OFF the controller power is
also reset, this error occurs in all axes.
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Main cause:
1. The internal data of the encoder is not maintained due to a deterioration of the encoder backup
battery voltage, disconnection of the encoder harness, defective encoders, etc.
2. When the controller power is turned OFF due to abnormal power supply, etc. during the robot
motion, the arm cannot stop its motion immediately. Because of this, a discrepancy may be
caused between the last encoder value recorded by AS software and the current value at the
actual position of stoppage.
3. Initializing is executed. (This error occurs in all axes.)
4. The motor or the encoder is replaced.
5. The arm (motor) is moved forcibly during the controller power OFF.
Countermeasure:
1. Perform zeroing of the encoder promptly after replacing the motor or the encoder.
！
WARNING
There is a possibility that the internal data of the encoder is not
maintained when this error occurs. Therefore, confirm without fail that
angle value for each axis becomes 0 after setting all axes to their scribe
marks (mechanical origin) in teach mode. If the angle values do not
become 0, execute zeroing without fail.
！
CAUTION
After the error reset, automatic operation is possible.
However, beware there is a high possibility of causing
malposition of the robot as the current value goes out of order.
Do not fail to confirm the above-mentioned zeroing and the
playback of steps in check mode.
2. Check the battery for the encoder backup, and when it decreases to +3.3 V or less, replace the
battery promptly. Replace the encoder batteries used in all axes, including conveyor, at the
same time.
3. Check for disconnection or short-circuit in the encoder harness.
4. Replace the encoder, encoder battery backup board, etc.
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Error code
: E1032
Error message : Mismatch ABS and INC encoder data (JtXX).
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
A large difference was detected between the number of encoder rotations from the servo board
and the number of rotations calculated in the servo software. This is detected by the servo
software.
Encoder
Encoder
Encoder
I/F
Servo
CPU
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. Defect in the encoder.
2. Defect in servo board.
Countermeasure:
1. Replace the encoder.
2. Replace the servo board.
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Error code
: E1034
Error message : Encoder initialize error (jtXX).
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
This error occurs when the encoder is rotating at 300 rpm or more at controller power ON, the
absolute position data cannot be fixed.
Encoder
Servo
CPU
Encoder
Encoder
I/F
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. The motor (encoder) was rotating at 300 rpm or more at controller power ON. (This also
applies to the conveyer encoder, etc.)
2. Defect in the encoder.
3. Defect in the servo board.
Countermeasure:
1. Set the motor (encoder) to rotate less than 300 rpm at controller power ON.
2. Replace the encoder.
3. Replace the servo board.
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Error code
: E1035
Error message : Encoder response error (JtXX).
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The encoder does not respond to the servo board or the response is slow.
Encoder
Servo
CPU
Encoder
Encoder
I/F
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. Disconnection or short-circuit of the encoder harness.
2. Defect in the encoder.
3. Defect in the servo board.
Countermeasure:
1. Check for disconnection or short-circuit in the encoder harness.
2. Replace the encoder.
3. Replace the servo board.
[NOTE]
After error reset, execute the robot program slowly in repeat
mode or move the robot carefully in teach mode.
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Error code
: E1036
Error message : Encoder communication error. (JtXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Abnormality in the CRC or framing error is detected in the communication with the encoder.
CRC abnormal
Framing abnormal
: Abnormality is detected by processing the data where the CRC data is
added to the communicated encoder data.
: The stop bit is not detected in the encoder data.
Encoder
Encoder
Encoder
I/F
Servo
CPU
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. Defect in the encoder.
2. Defect in the servo board.
Countermeasure:
1. Replace the encoder.
2. Replace the servo board.
[NOTE]
After error reset, execute the robot program slowly in repeat
mode or move the robot carefully in teach mode.
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Error code
: E1038
Error message : Encoder ABS-track error. (JtXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
There is a discrepancy between the absolute data and the incremental data in the encoder.
Encoder
Encoder
Encoder
I/F
Servo
CPU
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. Defect in the encoder.
2. Defect in the servo board.
Countermeasure:
1. Replace the encoder.
2. Replace the servo board.
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Error code
: E1039
Error message : Encoder INC-pulse error. (JtXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An abnormal pattern is detected in the output signal of the incremental pulse from the encoder.
Encoder
Encoder
Encoder
I/F
Servo
CPU
Servo board
Encoder power
supply +12 V
Power supply
circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. Defect in the encoder.
2. Defect in the servo board.
Countermeasure:
1. Replace the encoder.
2. Replace the servo board.
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Error code
: E1041
Error message : Limit switch (JtXX) is ON.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Robot went beyond the set motion range (restricted space) and activated the axis restriction limit
switch.
Set the motion range of each axis in Aux. function 0507 Motion Limits. Normally, the
maximum motion range of the robot is set at factory shipment.
To change the setting of the motion range, take into consideration the following conditions.
Maximum
operating
range
>
Mechanical
stopper
>
Axis restriction
>
limit switch
Set motion
range
(restricted space)
The mechanical stopper and the axis restriction limit switch are options, and the axis in which
they are installed varies with arm model and configuration. Typically, the AS software restricts
robot motion so as not to exceed the set motion range.
Axis
restriction
LS
Axis
restriction
LS
FPGA
Encoder battery backup board
Servo board
Controller
Robot arm
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Main cause:
1. Due to an incorrect setting of the zeroing data, manual brake release, etc., the robot was moved
out of the set motion range (restricted space), and the axis restriction limit switch was turned
ON.
2. With the axis restriction limit switch ON, the motion range was set larger than the current
values.
3. The axis restriction limit switch harness was disconnected when the robot was outside of the
set motion range.
4. If the set motion range was close to the set angle of the axis restriction limit switch, the limit
switch may have been turned ON due to overshoot of the robot.
5. Disconnection, etc. in the axis restriction limit switch harness.
6. Defect in the servo board.
Countermeasure:
1. When this error occurs, the motor power can be turned ON while pressing and holding down
the override switch on the power sequence board. Move the arm by teach mode into the
motion range.
2. Or, use the (optional) manual brake release switch and release the brake manually to move the
arm into the motion range when the power cannot be turned ON. At this time, turn OFF the
motor power and release all Emergency Stops without fail.
3. Set the motion range to an appropriate value.
4. Change placement of the axis restriction limit switches appropriately.
5. Check the harness or the axis restriction limit switch, and replace them if necessary.
6. Replace the servo board.
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Error code
: E1109
Error message : Conveyor I/F board is not installed.
Error processing : Display
Error reset : Acceptable
Content:
Although an incremental type encoder is set to be used as a conveyor encoder, the conveyor I/F
board (1SQ board) which is to be used as the I/F board for the encoder is not mounted.
Main cause:
1. The conveyor I/F board is not mounted.
2. Defect in the conveyor I/F board.
3. Defect in the power sequence board on which the conveyor I/F board is mounted.
Countermeasure:
1. Mount the conveyor I/F board.
2. If the same error occurs after mounting the conveyor I/F board, replace the power sequence
board.
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Error code
: E1118
Error message : Command value for JtXX suddenly changed.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
[Command value - Current value] calculated for each axis in repeat mode exceeded the following
value.
Rated axis max. speed ×1.3 (Rated axis max. speed varies depending on the robot model and
axis.)
Main cause:
1. During a robot motion, a sudden motion change occurred.
2. Defective connection of the harness, etc.
3. Defect in the servo board, the power block, etc.
Countermeasure:
1. Modify the teach data so that no sudden changes occur.
2. Check each harness and board since defective connection of the harness, servo abnormalities,
etc., may be possible causes of the malfunction.
3. Replace the servo amplifier unit.
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Error code
: E1119
Error message : Command value for JtXX beyond motion range.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The command value for each axis has exceeded the set motion range (restricted space) in teach
mode, check mode or repeat mode.
Set the motion range of each axis in Aux. function 0507 Motion Limits. Normally, the
maximum motion range of the robot is set at factory shipment.
Main cause:
1. Incorrect setting of the motion range.
2. Poses near the motion limits was taught in the program.
Countermeasure:
1. Modify motion range to appropriate one.
2. Change the teaching point(s) in the program.
To change the setting of the motion range, take into consideration the following conditions.
Maximum
operating
range
>
Mechanical
stopper
>
Axis restriction
>
limit switch
Set motion range
(restricted space)
The mechanical stopper and the axis restriction limit switch are options, and the axis in which
they are installed varies with arm model and configuration.
[NOTE]
An initial listing of set values is enclosed with the controller of each machine or
with the manuals at factory shipment. Confirm the value settings with this list.
Keep this list for future use. When changing any setting, record the new
values. (E.g.: changing of options, motion range settings, etc.)
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Error code
: E1120
Error message : Current command causes interference betw Jt2 and Jt3.
Error processing : Display
Error reset : Acceptable
Content:
Command values of the second and third axes are interfering with each other, for robots whose
second and third axes are a link mechanism, such as Z series, etc.
(For robots whose second and third axes are not a link mechanism, such as R series, this error is
not detected.)
Main cause:
Inappropriate teaching data, including the pose while moving.
Countermeasure:
Modify the teaching data.
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Error code
: E1123
Error message : Speed error JtXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Each axis speed (motor speed) calculated from the encoder value exceeded the rated value. This
is detected by the servo software.
Main cause:
1. The arm fell: due to disconnection of the motor power line U, V, or W phases, or a defect in the
power block.
2. Malfunction due to wiring failure in the motor power line or the encoder line.
3. Disconnection or short-circuit in the encoder harness, or defect in the encoder.
4. A sudden change in the robot motion.
5. Defect in the servo board.
6. The required inertia moment exceeded the motor torque limit while moving at maximum speed
because load exceeded the rated load.
Countermeasure:
1. Check for disconnection or short-circuit in the harness.
2. Replace the servo amplifier unit.
3. Replace the encoder.
3. If sudden changes in robot motion occur, modify the teach data so that the poses are corrected,
the speed becomes lower, etc.
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Error code
: E1124
Error message : Deviation error of JtXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The difference between the present value of the encoder and the command value of the AS
software exceeded a rated value. This is detected by the servo software. The rated value
differs depending on robot models, axes, etc.
Main cause:
1. Mechanical factors:
(1) Robot arm came in contact with the jig, etc.
(2) Cables, etc. were caught by the robot arm.
(3) The reducer, gear, bearing, etc. are damaged.
(4) The backlash is too small in the gear reduction part.
(5) The payload exceeds robot rated weight.
(6) A robot motion pattern repeated which results in exceeding the rated motor capacity (due to
shuttle movement, etc.).
(7) The motor brake is not released.
2. Electric factors:
(1) Motor power line U, V, and W phases are disconnected. (No disconnection check is
performed.)
(2) Defect in the power block.
(3) Defect in the servo board.
(4) Defect in the MC unit.
(5) Disconnection between the servo board (X503, X504, X505) and MC unit (X304).
(6) Disconnection, etc. in the PN power supply wiring between the MC unit (X352, X353) and
servo amp. unit.
(7) Defect in the motor.
3. A sudden change motion occurred.
Countermeasure:
1. When the robot arm interfered with something, move it away from the interference in teach
mode. Then, check for defects in the drive parts, reducers, etc., and for positioning deviation
caused by arm deformation.
2. When parts (reducers, etc.) are damaged, check and replace them if necessary.
3. If the payload or the motion pattern causes the error, modify them.
4. If an electrical factor is causing the error, check the harness, servo amp. unit, MC unit, motor,
etc., and replace them if necessary.
5. If there are sudden changes in robot motion, modify the teach data.
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Error code
: E1128
Error message : Uncoincidence error betw destination and current JtXX pos.
Error processing : Display
Error reset : Acceptable
Content:
The command value arrived at the destination but the current value does not arrive at the accuracy
setting range after a certain period of time elapsed This is detected by the AS software.
Main cause:
1. Mechanical factors:
(1) The axis load has become too large due to defective reducer, bearing, etc.
(2) The backlash is too small in the gear reduction part.
(3) Robot arm made contact with the jig, etc., or the cables, etc. are caught by the robot arm.
(4) The motor brake is not released.
2. Electric factors:
(1) Motor power line U, V, and W phases are disconnected. (No disconnection check is
performed.)
(2) Defect in the power block.
(3) Defect in the servo board.
(4) Defect in the MC unit.
(5) Disconnection between the servo board (X503, X504, X505) and MC unit (X304).
(6) Disconnection, etc. in the PN power supply wiring between the MC unit (X352, X353) and
servo amp. unit.
(7) Defect in the encoder or disconnection of the encoder.
3. Defect in the teach data:
During linear interpolation motion, after being calculated to maintain the orientation of the tool on
the XYZ coordinates system, the command values are usually converted into joint command
values and then used for operating. However, this error might occur when the angle of the wrist
axis between the start and the end steps differs largely (such as opposite direction for JT6, etc.)
even if the tool orientation taught at the start and end points of robot motion are the same in OAT
values of the orientation.
Countermeasure:
1. In the case of mechanical failures, replace the reducers, etc. or adjust the backlash, etc.
2. In the case of electric failures, replace the harness, servo amp. unit, MC unit, encoder etc.
and replace them if necessary.
3. Modify the teach data if the error occurs in a specific program step.
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Error code
: E1262
Error message : Encoder rotation speed exceeded limit (JtXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An error was detected because encoder rotation speed exceeded the 7700 rpm limit value.
Main cause:
Inappropriate teach data to exceed the limit value in encoder rotation.
Countermeasures:
1. Modify the teach data by repositioning the taught point, etc. so that the speed reduces in the
area where error occurred.
2. Replace the encoder.
3. If error cannot be solved after taking countermeasures above, report all details to Kawasaki,
including information of all messages, robot model, controller model, machine number,
AS/servo software versions, operation at time of error, the contents of program lists, equipped
options, etc.
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Error code
: E1263
Error message : Encoder temperature exceeded limit (JtXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An error was detected because encoder temperature exceeded the limit value.
Main cause:
Inappropriate teach data to apply overload while moving.
Countermeasures:
1. Modify the teach data by reducing the speed of acceleration/deceleration or by extending
waiting time, etc. so that load is reduced on the axis where error occurred.
2. Replace the encoder.
3. If error cannot be solved after taking countermeasures above, report all details to Kawasaki,
including information of all messages, robot model, controller model, machine number,
AS/servo software versions, operation at time of error, the contents of program lists, equipped
options, etc.
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Error code
: E1267
Error message : The initial setting of encoder is abnormal. (JtXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Settings that is made during encoder initialization did not complete successfully.
Initialization settings:
The abnormal detection value for encoder rotation speed is set at 7700 rpm.
The abnormal detection value for encoder temperature is set at 95 °C
Main cause:
Failed to write to the encoder memory or defect in the encoder line.
Countermeasures:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. Replace the encoder.
3. Check for disconnection in the encoder line.
4. If error cannot be solved after taking countermeasures above, report all details to Kawasaki,
including information of all messages, robot model, controller model, machine number,
AS/servo software versions, operation at time of error, the contents of program lists, equipped
options, etc.
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Error code
: E1268
Error message : Breakage in the encoder line or faulty setting of encoder baud rate. (JtXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
When turning ON the controller power, encoder baud rate did not switch to 4 Mbps, or the baud
rate switched to 4 Mbps but the state was not recognized as having been switched.
Main cause:
Disconnected or unconnected encoder line, or failed to write to the encoder memory.
Countermeasures:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. Confirm the encoder is formatted in A.
3. Replace the encoder.
4. Check for disconnection in the encoder line.
5. Replace the servo board.
6. If error cannot be solved after taking countermeasures above, report all details to Kawasaki,
including information of all messages, robot model, controller model, machine number,
AS/servo software versions, operation at time of error, the contents of program lists, equipped
options, etc.
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Error code
: E1287
Error message : Power module error JtXX (UPPER).
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The power module has detected an error signal in the power block.
Motor
Robot
m ain body
PW M signal
HIC
IPM
IPM error signal
Servo
1KB board
board
Power block
Controller
Main cause:
1. Defective power block connection with the servo board.
2. IPM control power voltage (+15 V, upper side) decreased.
3. Short-circuit current flowed.
4. IGBT chip temperature increased in the IPM.
5. Defect in the IPM.
Countermeasure:
1. Check if the servo board is mounted correctly.
2. Check for the wiring, and connection of the connectors in the servo amplifier unit.
3. Check if the U-phase, V-phase, or W-phase in the motor is short-circuited or grounded.
4. Check the cooling devices such as cooling fan, etc., or fan running time setting.
5. Replace the servo amplifier unit.
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Error code
: E1288
Error message : Power module error JtXX (LOWER).
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The power module has detected an error signal in the power block.
Motor
Robot
m ain body
PW M signal
HIC
IPM
IPM error signal
Servo
1KB board
board
Power block
Controller
Main cause:
1. Defective power block connection with the servo board.
2. IPM control power voltage (+15 V, upper side) decreased.
3. Short-circuit current flowed.
4. IGBT chip temperature increased in the IPM.
5. Defect in the IPM.
6. Defective DC power supply in the MC unit.
Countermeasure:
1. Check if the servo board is mounted correctly.
2. Check for the wiring, and connection of the connectors in the servo amplifier unit.
3. Check if the U-phase, V-phase, or W-phase in the motor is short-circuited or grounded.
4. Check the cooling devices such as cooling fan, etc., or fan running time setting.
5. Replace the servo amplifier unit.
6. Replace the MC unit.
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Error code
: E1289
Error message : [Servo boardXX]Synchronous error.(Servo FPGA)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Synchronous operation failed between the servo board CPU and servo FPGA.
Main cause:
Defect in the servo board.
Countermeasure:
1. Turn the AC primary power OFF and then ON, and check if the same error occurs.
2. Replace the servo board if the same error occurs.
3. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: E1290
Error message : JtXX Voltage of the current sensor exceeded the upper limit.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The motor current detected by the motor current detection circuit in the power block board
exceeded the upper limit.
Servo FPGA
Current feedback
Servo board
PMW
Current
detection
circuit
IPM
Power block
Each
motor
Robot main body
Controller
Main cause:
1. Defect in the power block board.
2. Defect in the servo board.
3. Ground fault or short-circuit in the motor power line.
4. Defect in the motor.
Countermeasure:
1. Replace the servo amplifier unit.
2. Check for ground fault or short-circuit in the motor power line.
3. Replace the motor.
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Error code
: E1291
Error message : JtXX Current sensor is disconnected or out of order.(U)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The U-phase motor current detection circuit is defective in the power block board, or the signal
line to the servo board is abnormal.
Servo FPGA
Current feedback
Servo board
PMW
Current
detection
circuit
IPM
Power block
Each
motor
Robot main body
Controller
Main cause:
1. Defect in the power block board.
2. Defect in the servo board.
3. Defective connection of connectors between the power block and servo board.
Countermeasure:
1. Replace the servo amplifier unit.
2. Replace the servo board.
3. Check the connection of connectors between the power block and servo board.
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Error code
: E1292
Error message : [Servo boardXX]Abnormal signal input from MCXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Power supply abnormal signal is input from the MC control board.
Main cause:
1. Inappropriate voltage adjustment in the AVR for control power.
2. Defect in the AVR for control power.
3. Defect in the MC unit (MC control board).
4. Defect in the servo board.
5. Ground fault or short-circuit in the 5 V wiring.
6. Disconnection in the harness between the servo board (X503, X504, X505) and MC unit
(X304).
Countermeasure:
1. Check the 5 V between test pins on the power sequence board, then adjust the voltage so that it
becomes within 5.05 – 5.15 V.
2. Replace the AVR.
3. Replace the MC control board.
4. Replace the servo board.
5. Check for the ground fault or short-circuit in the 5 V wiring.
6. Check the harness between the servo board (X503, X504, X505) and MC unit (X304).
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Error code
: E1293
Error message : [Servo boardXX]Current feedback gain is abnormal.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
In the servo board, the current setting value that is set in the CPU for servo FPGA is different
between the write and read values.
Main cause:
Defect in the servo board.
Countermeasure:
Replace the servo board.
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Error code
: E1294
Error message : [Servo boardXX]I/O 24V is low.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Decrease of the IO24 V which is generated in the servo board is detected.
Main cause:
1. Ground fault or short-circuit in the IO24 V line.
2. Decrease of 24 V power supply in the AVR for control power.
3. Disconnection, etc. in the 24 V wiring.
4. Defect in the servo board.
Countermeasure:
1. Check for any ground fault or short-circuit in the IO24 V line, such as machine harness, X3
signal harness, or harness connected from X9 connector of power sequence board.
2. Check the 24 V power supply voltage in the AVR, replace it if defective.
3. Check the 24 V wiring.
4. Replace the servo board.
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Error code
: E1295
Error message : [Servo boardXX]24V for internal valve is low.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Decrease of the 24 V power supply for machine valve is detected. The 24 V is generated in the
optional machine valve/sensor board which is mounted on the servo board.
Main cause:
1. Ground fault or short-circuit in the 24 V line for the machine valve.
2. Defect in the optional machine valve/sensor board.
3. Defect in the servo board.
Countermeasure:
1. Check for ground fault or short-circuit in the 24 V line for machine valve, such as machine
harness, or separate harness.
2. Replace the optional machine valve/sensor board on the servo board.
3. Replace the servo board.
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Error code
: E1296
Error message : [Servo boardXX]Mismatch in safety circuit LS conditions.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Contacts state for axis restriction limit switch(LS) does not match between the first and second
safety circuits.
Main cause:
1. Defective input circuit or wiring in the axis restriction LS input in the robot arm. Or only the
first circuit is input.
2. Disconnection or ground fault in the wiring of the axis restriction LS.
3. Defect in the axis restriction LS.
4. Defect in the servo board.
Countermeasure:
1. Check the wiring of the axis restriction LS in the robot arm.
2. Replace the axis restriction LS.
3. Replace the servo board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both
first and second circuits. When they are ON, error reset cannot be executed.
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Error code
: E1297
Error message : [Servo boardXX]Mismatch in jumper wiring for detecting internal pressure.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
In the X510 wiring connected to the servo board, connection state of the safety circuit jumper
harness does not match between the first and second circuits.
Main cause:
1. Disconnection in the X510 connector part.
2. Defect in the servo board.
Countermeasure:
1. Check theX510 connector part.
2. Replace the servo board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both first
and second circuits. When they are ON, error reset cannot be executed.
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Error code
: E1298
Error message : [Servo boardXX]Mismatch in contact condition of LS override switches.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The limit switch override switch state does not match between the first and second switches.
Main cause:
1. Disconnection or short-circuit in the limit switch override switch lines.
2. Defect in the limit switch override switch (on the power sequence board).
3. Defect in the servo board.
4. Defect in the mother board.
Countermeasure:
1. Check for the disconnection or short-circuit in the wiring between the mother board (X206)
and servo board (X502).
2. Replace the power sequence board.
3. Replace the servo board.
4. Replace the mother board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both first
and second circuits. When they are ON, error reset cannot be executed.
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Error code
Error message
: E1299
: [Servo boardXX]Jumper wiring for detecting internal pressure is
disconnected.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The jumper line (X510) is not connected in the safety circuit on the servo board.
Main cause:
1. Defective connection in the jumper line (X510) connected to the servo board.
2. Defect in the servo board.
Countermeasure:
1. Check the X510 connector line connected to the servo board.
2. Replace the servo board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1300
Error message : [Servo boardXX]DC 24V is abnormal.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The 24 V voltage supplied to the servo board from the AVR for control power became deviated
from the rated value.
Main cause:
1. Defect in the AVR for control power.
2. Defect in the servo board.
3. Defect in the MC unit.
4. Defect in the mother board.
5. Ground fault, short-circuit, or disconnection in the 24 V wiring.
Countermeasure:
1. Replace the AVR.
2. Replace the servo board.
3. Replace the MC unit.
4. Replace the mother board.
5. Check the 24 V wiring for any abnormality.
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Error code
: E1301
Error message : [Servo b’dXX]Encoder type mismatch between software and servo board.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The servo software setting does not match the jumper switch setting in the servo board.
Main cause:
1. Incorrect setting of the jumper connector (J2) on the servo board.
2. Incorrect servo software version.
3. Defect in the servo board.
Countermeasure:
1. Check the setting of the jumper connector (J2) on the servo board.
2. Check the servo software version.
3. Replace the servo board.
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Error code
: E1302
Error message : [MCXX]OFF check is abnormal.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The OFF state of the magnetic contactor (K1 or K2) in the MC unit is not detected before motor
power ON.
Main cause:
1. Defect in the magnetic contactor (K1 or K2) in the MC unit.
2. Disconnection or defective connection in the harness inside the MC unit.
3. Defect in the MC control board.
Countermeasure:
Replace the MC unit.
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Error code
: E1303
Error message : [MCXX]OFF check of safety relay is abnormal.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The OFF state of the safety relay (KS1 or KS2) in the MC control board is not detected before
motor power ON.
Main cause:
Defect in the MC control board.
Countermeasure:
Replace the MC control board.
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Error code
: E1304
Error message : [MCXX]Incorrect operation of K1.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The magnetic contactor (MC) K1 in the MC unit does not operate properly.
Main cause:
1. Defect in the MC(K1) in the MC unit.
2. Disconnection or defective wiring in the harness of the MC unit.
3. Defect in the MC control board.
Countermeasure:
1. Replace the MC unit.
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Error code
: E1305
Error message : [MCXX]Incorrect operation of K2.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The magnetic contactor (MC) K2 in the MC unit does not operate properly.
Main cause:
1. Defect in the MC(K2) in the MC unit.
2. Disconnection or defective wiring in the harness of the MC unit.
3. Defect in the MC control board.
Countermeasure:
1. Replace the MC unit.
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Error code
: E1306
Error message : [MCXX]Incorrect operation of inrush current control relay.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The inrush current control relay on the MC board does not operate properly.
Main cause:
1. Defect in the MC power board of the MC unit.
2. Defect in the MC control board.
3. Disconnection or defective wiring in the harness of the MC unit.
Countermeasure:
1. Replace the MC unit.
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Error code
: E1307
Error message : [MCXX]Incorrect operation of safety relay KS1.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The safety relay (KS1) in the MC control board does not operate properly.
Main cause:
Defect in the MC control board.
Countermeasure:
Replace the MC control board.
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Error code
: E1308
Error message : [MCXX]Incorrect operation of safety relay KS2.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The safety relay (KS2) in the MC control board does not operate properly.
Main cause:
Defect in the MC control board.
Countermeasure:
Replace the MC control board.
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Error code
: E1309
Error message : [MCXX]Incorrect operation of safety relay KS3.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The safety relay (KS3) in the MC control board does not operate properly.
Main cause:
Defect in the MC control board.
Countermeasure:
Replace the MC control board.
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Error code
: E1310
Error message : [MCXX]Incorrect operation of motor ON relay.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The motor ON relay in the MC control board does not operate properly.
Main cause:
Defect in the MC control board.
Countermeasure:
Replace the MC control board.
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Error code
Error message
: E1311
: [MCXX]Incorrect operation of safety circuit motor OFF relay.(Servo
boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The motor OFF relay in the MC control board does not operate properly.
Main cause:
Defect in the MC control board.
Countermeasure:
Replace the MC control board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1312
Error message : [MCXX]Mismatch in safety circuit motor OFF relay.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The contact state of the motor OFF relay in the MC control board does not match between the
first and second contacts.
Main cause:
Defect in the MC control board.
Countermeasure:
Replace the MC control board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both first
and second circuits. When they are ON, error reset cannot be executed.
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Error code
Error message
: E1313
: [MCXX]Mismatch in individual MC control of safety circuit.(Servo
boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The contact state for individual power cut OFF connected to X301 connector of the MC control
board does not match between the first and second contacts.
Main cause:
1. Defective wiring connected to X301 connector of the MC control board (only the first contact
is connected, etc.) or defect in the contact.
2. Defect in the MC control board.
Countermeasure:
1. Check if the wiring to X301 is proper, or the contact has no defects.
2. Replace the MC control board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both first
and second circuits. When they are ON, error reset cannot be executed.
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Error code
: E1314
Error message : [MCXX]Thyristor Thermal is abnormal.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Overheat or thermal signal of the three-phase rectification module on the MC power board is
detected in the MC control board.
Main cause:
1. Abnormal cooling fan on top of the amplifier unit for single axis.
2. Defect in the MC power board of the MC unit.
3. Disconnection or defective connection in the harness inside the MC unit.
4. Defect in the MC control board.
Countermeasure:
1. Check if the fan on top of the amplifier unit for single axis operates properly.
2. Replace the MC unit.
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Error code
: E1315
Error message : Watchdog error in NoXX I/O board.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The bus access from the main CPU board to the IO board was not made for a certain period of
time (250 ms) or more.
Main cause:
1. Defect in the main CPU board.
2. Defect in the IO board.
3. Defect in the mother board.
Countermeasure:
1. Turn the AC primary power OFF and then ON, and check if the same error occurs.
2. Replace the main CPU board.
3. Replace the IO board.
4. Replace the mother board.
5. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: E1316
Error message : [I/O board(No.XX)]Access Error.[Address:XX][Code:XX]
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Abnormal access with IO board occurs.
Main cause:
Abnormal device driver.
- The address represents that in which process the error occurred.
- The code represents return value from the IO board device driver at error occurrence.
Countermeasure:
1. Reset the error. If it cannot be reset, turn the controller power OFF and then ON. If a
message for initialization appears, select <NO>.
2. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
3. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board.
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Error code
: E1318
Error message : [MCXX]DC 20V is abnormal.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The 20 V power supply voltage for IPM inside the MC unit deviated from the rated value.
Main cause:
Inside the MC unit,
1. Disconnection or defective connection in the controller harness X380.
2. Phase defect in the R-phase or S-phase.
3. Defect in the power supply for IPM.
4. Defect in the MC power board inside the MC unit.
5. Disconnection or defective connection in the harness inside the MC unit.
6. Defect in the MC control board.
7. Defect in the power block board.
Countermeasure:
1. Check the controller harness X380 line.
2. Check for phase defect in the R-phase or S-phase.
3. Replace the MC unit.
4. Replace the servo amplifier unit.
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Error code
: E1321
Error message : [Main CPU board]Servo board(XX) communication error. (CodeXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An abnormal communication occurred continuously, exceeding the rated communication cycle
between the main CPU board and the servo board.
Main cause:
The cause of the error is displayed in the last 8 numbers of the code. The code shows the error
details of the last two communication cycles. The first four numbers shows the latest cycle error,
while the last four numbers shows the error of one cycle before the latest cycle.
There are following codes for the error:
1) 0001
Error when processing sending data from the main CPU board.
2) 0002
Error when processing receiving data by the main CPU board. (Data from the servo
board could not be received.)
3) 0004
The two counters values for communication control do not match among the data
received from the servo board.
4) 0008
The counter value for communication control is the same as the previous value
among the data received from the servo board.
5) 0010
The counter value for communication control is not consecutive among the data
received from the servo board.
Countermeasure:
If the same error occurs after executing error reset, process the followings for each code.
1) 0001
2) 0002
3) 0004
4) 0008
5) 0010
Replace the main CPU board.
1. Check if the communication harness between the main CPU board and servo board
is connected properly.
2. Replace the communication harness → servo board → main CPU board.
Replace the communication harness → servo board → main CPU board.
Replace the communication harness → servo board → main CPU board.
Replace the communication harness → servo board → main CPU board.
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Error code
Error message
: E1322
: Setting num. of safety circuits differs betw. powerseq.b'd and MCXX. (Servo
b'dXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The DIP switch (SW2-1) setting for specifying the number of safety circuits on the power
sequence board does not match the jumper setting (JP2 or JP3) in the MC control board.
Main cause:
1. Incorrect switch settings on the power sequence board or MC control board.
2. Defect in the power sequence board.
3. Defect in the MC control board.
Countermeasure:
1. Check if the jumper setting are correct between the DIP switch (SW2-1) in the power sequence
board and the jumper (JP2 or JP3) in the MC control board.
If the jumper setting is correct,
2. Replace the power sequence board.
3. Replace the MC control board.
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Error code
: E1323
Error message : Setting num. of safety circuits differs betw. servo b'dXX and MCXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The state of jumper (JP2 or JP3) setting for specifying the number of safety circuits on the MC
control board is not transmitted to the servo board properly.
Main cause:
1. Disconnection in the harness between the servo board (X503, X504, X505) and the MC control
board (X304).
2. Defect in the MC control board.
3. Defect in the servo board.
Countermeasure:
1. Check the harness between the servo board (X503, X504, X505) and the MC control board
(X304).
2. Replace the MC control board.
3. Replace the servo board.
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Error code
: E1324
Error message : Safe circuit disconnected between power sequence board and servo boardXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The wiring of the safety circuit is disconnected between the power sequence board and servo
board.
Main cause:
1. Disconnection or defective connection in the harness between the mother board and servo
board.
2. Defect in the power sequence board.
3. Defect in the servo board.
4. Defect in the mother board.
Countermeasure:
1. Check the harness between the mother board and servo board.
2. Replace the power sequence board.
3. Replace the servo board.
4. Replace the mother board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1325
Error message : Safe circuit disconnected between servo boardXX and MCXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The wiring of the safety circuit is disconnected between the servo board and MC unit.
Main cause:
1. Disconnection or defective connection in the harness between the servo board and MC unit.
2. Defect in the MC control board.
3. Defect in the servo board.
Countermeasure:
1. Check the harness between the servo board and MC unit.
2. Replace the MC control board.
3. Replace the servo board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1326
Error message : Safety fence is open.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The signal which shows that the safety fence is open input from outside.
Main cause:
1. The external contact connected to X8 connector (1-2 pin, 3-4pin) on the power sequence board
is open.
2. Defect in the power sequence board.
Countermeasure:
1. Check the signal which shows that the safety fence is open input from outside.
2. When that signal is not input, replace the power sequence board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
Error message
: E1327
: [Power sequence board]Miscompare in motor off relay condition on safety
circuit.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The contacts of the motor OFF relay on the power sequence board do not match between the first
and second contacts.
Main cause:
Defect in the power sequence board.
Countermeasure:
Replace the power sequence board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
[NOTE]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state(open state) in both first
and second circuits. When they are ON, error reset cannot be executed.
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Error code
: E1328
Error message : [Power sequence board]Error of motor off relay on safety circuit.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The motor OFF relay in the power sequence board does not operate properly.
Main cause:
Defect in the power sequence board.
Countermeasure:
Replace the power sequence board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1329
Error message : [Power sequence board]Error in TEACH/REPEAT switch on safety circuit.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The signal state that is not identified as either TEACH or REPEAT continued for
TEACH/REPEAT switch.
Main cause:
1. Defect in the TEACH/REPEAT switch.
2. Defective harness or unconnected harness connector between the TEACH/REPEAT switch
and mother board (X203).
3. Defect in the power sequence board.
4. Defect in the mother board.
Countermeasure:
1. Replace the TEACH/REPEAT switch.
2. Check for unconnected harness connector, defective connection, or disconnection in the
harness between the TEACH/REPEAT switch and mother board (X203).
3. Replace the power sequence board.
4. Replace the mother board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1330
Error message : [Power sequence board]IO 24V is low.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The IO24 V voltage supplied to the power sequence board from the servo board has decreased.
Or, the 24 V for the AVR for control power has decreased.
Main cause:
1. Ground fault or short-circuit of the IO24 V in the external wiring.
2. Defect in the AVR for control power.
3. Defect in the servo board.
4. Defect in the power sequence board.
5. Disconnection of the harness between the servo board (X501) and mother board (X207).
6. Defect in the mother board.
Countermeasure:
1. Check for ground fault or short-circuit of the IO24 V in the external wiring when the IO24 V is
used as an external wiring. (Ground fault or short-circuit may also occur in the wiring inside
the robot arm.)
2. When the error occurs at the same time as “D1560 DC 24V is abnormal.”, refer to
countermeasure for D1560.
3. Replace the servo board.
4. Replace the power sequence board.
5. Check for unconnected connector or disconnection in the harness between the servo board
(X501) and mother board (X207).
6. Replace the mother board.
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Error code
: E1331
Error message : [Power sequence board]Thermal error.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The thermal switch (70°C) for monitoring controller temperature activated in the power sequence
board.
Main cause:
1. Rotation speed of the cooling fan decreased in the controller.
2. The ambient temperature of the controller increased up to 45°C or more.
3. Defect in the power sequence board.
Countermeasure:
1. When the error “W1053: Rotational speed of fan is below the limit” is occurring, refer to the
countermeasure for W1053.
2. Check if the ambient temperature of the controller is 45°C or below.
3. Replace the power sequence board.
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Error code
: E1332
Error message : [Power sequence board]Power error signal was input from servo boardXX.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The DC voltage in the servo board has decreased.
Main cause:
1. Inappropriate voltage adjustment in the AVR for control power.
2. Defect in the AVR for control power.
3. Defect in the servo board.
4. Defect in the power sequence board.
5. Disconnection or unconnected connector in the harness between the servo board (X501) and
mother board (X207).
6. Defect in the mother board.
Countermeasure:
1. Check the 5 V between test pins on the power sequence board, then adjust the voltage so that it
becomes within 5.05 – 5.15 V.
2. Replace the AVR for control power.
3. Replace the servo board.
4. Replace the power sequence board.
5. Check for unconnected connector or disconnection in the harness between the servo board
(X501) and mother board (X207).
6. Replace the mother board.
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Error code
: E1333
Error message : Motor power ON signal has turned off.(Servo boardXX)(MCXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Although the motor power is ON in the AS software, other errors are not detected and motor ON
state signal transmitted to the servo board from the MC unit does not become ON or the signal
stopped.
Main cause:
1. Defect in the MC unit (MC control board).
2. Defect in the servo board.
3. Disconnection between the MC unit and servo board.
Countermeasure:
1. Replace the MC control board.
2. Replace the servo board.
3. Check the harness between the MC unit (X304) and servo board (X503 for MC unit 1, X504
for MC unit 2, X505 for MC unit 3).
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Error code
Error message
: E1334
: TEACH/REPEAT switch is abnormal.(Mode differs betw. safety circuit and
monitor.)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
There is a discrepancy in the state signals for TEACH/REPEAT switch (between the safety
circuit and control monitor signal).
Main cause:
1. Defect in the TEACH/REPEAT switch.
2. Defective harness between the TEACH/REPEAT switch and mother board (X203).
3. Defect in the power sequence board.
4. Defect in the mother board.
Countermeasure:
1. Replace the TEACH/REPEAT switch.
2. Check for defective connection or disconnection in the harness between the TEACH/REPEAT
switch and mother board (X203).
3. Replace the power sequence board.
4. Replace the mother board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1335
Error message : Unexpected motor powerOFF.(Servo boardXX)(MCXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Although the motor power is ON in the AS software, other errors than this is not detected and the
safety relay in the MC unit or magnetic contactor is not activated, or they stopped.
Main cause:
1. Defect in the MC unit.
2. Defect in the servo board.
3. Defect in the power sequence board.
4. Disconnection between the mother board and servo board.
5. Disconnection between the MC unit and servo board.
6. Unconnected connector X301 in the MC unit.
Countermeasure:
1. Replace the MC unit.
2. Replace the servo board.
3. Replace the power sequence board.
4. Check the wiring between the mother board (X206) and servo board (X502).
5. Check the wiring between the MC unit (X304) and servo board (X503, X504, X505).
6. Check the connector X301 in the MC unit.
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Error code
: E1336
Error message : [Servo boardXX]Communication error with Main CPU board.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An error is detected by the servo board in communication between the main CPU board and servo
CPU board.
Main cause:
1. Defect in the wiring between the mother board and servo board. (When two or more servo
boards are used, in the wiring between the additional servo communication board and servo
board.)
2. Defect in the servo board.
3. Defect in the main CPU board or additional servo communication board.
4. Defect in the mother board.
Countermeasure:
1. Check if the error is resolved by executing error reset.
2. Check the wiring between the mother board (X206) and servo board (X502).
3. Replace the servo board.
4. Replace the main CPU board or additional servo communication board.
5. Replace the mother board.
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Error code
: E1337
Error message : [MCXX]Brake power is abnormal.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The brake power supply voltage (DC26 V) generated in the MC unit deviated from the rated
value.
Robot
main body
Motor
Motor brake line
Controller
MC power board
Brake power supply
Transformer
Protector
DC26V
Safety circuit
Brake power supply error signal
CPU
Brake release signal
Voltage detect.
MOSFET
Brake line error signal
MC control board
Servo board
Main cause:
1. Circuit protector (CP) activated due to short-circuit or ground fault in the brake power
supply lines.
2. Defect in the wiring for input to transformer for the brake power supply or in the wiring
from the transformer to the MC power board.
3. Defect in the MC power board.
4. Defect in the MC control board.
5. Short-circuit or ground fault of the harness inside the MC unit.
6. Short-circuit or ground fault of the fan wiring. (Fan for servo amp. unit excluded.)
Countermeasure:
1. Restore the circuit protector to a normal state if it activated.
2. Replace the MC unit.
3. Check the input/output wiring lines in the transformer for brake power supply.
4. Check the fan wiring lines.
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Error code
: E1338
Error message : [MCXX]P-N low voltage.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The motor power voltage (P-N power voltage) is at the rated value (DC150 V) or less when the
motor power is turned ON or while it is ON.
[NOTE]
Beware when low voltage occurs, the arm will fall until the error is detected
because the motor power is not supplied during servoing. As a result, other
errors such as abnormal speed, abnormal deviation, etc. might be detected.
Main cause:
1. Disconnection or defective connection in the harness inside the MC unit.
2. Defect in the MC power board.
3. Defect in the MC control block.
4. Disconnection or defective connection in the harness between the MC unit (X352, X353) and
power block board.
5. Defect in the power block board.
Countermeasure:
1. Replace the MC unit.
2. Check for any abnormality in the harness between the MC unit (X352, X353) and power block
board.
3. Replace the servo amplifier unit.
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Error code
: E1339
Error message : [MCXX]P-N high voltage.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The motor power voltage (P-N power voltage) is at the rated value (DC410 V) or more when the
motor power is turned ON or while it is ON.
Main cause:
1. Inappropriate teaching causing excessive regeneration was executed.
2. Defect in the MC power board.
3. Disconnection of the regenerative resistor harness or defective regenerative resistor.
4. Defect in the MC control board.
5. Defect in the additional regenerative resistor (option).
Countermeasure:
1. When the regenerating current is excessive, modify the teaching, or reduce the repeat speed.
2. When the motion requires greater resistance capacity, install another additional regenerative
resistor.
3. Replace the MC unit.
4. Replace the regenerative resistor.
5. Replace the additional regenerative resistor.
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Error code
: E1340
Error message : [MCXX]Regenerative time over.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Regeneration time continued for 6 seconds or more in the MC power board.
The term “regeneration” here means as follows: When the robot decelerates, the motor
generates power by absorbing the inertia energy of the robot arm, and the power may cause
overvoltage between P-N of the motor. To prevent the overvoltage, current is set to distribute to
regenerative resistor from the MC unit when the P-N voltage exceeds a rated value.
MC unit
MC control board
CPU
MC power board
Regeneration
state signal
Regenerative
circuit
Regenerative
resistor
Main cause:
1. Defect in the MC power board.
2. Defect in the MC control unit.
3. Defective harness connection between the MC control board and MC power board inside the
MC unit.
4. If the error occurs during connection with the additional regenerative resistor (option), the
resistor itself may be defective.
5. Inappropriate teaching causing regeneration for 6 sec. in a row was executed.
6. Defect in the servo board.
Countermeasure:
1. Replace the MC unit.
2. Check the model and connection of the additional regenerative resistor. When it is connected
properly, replace the additional regenerative resistor.
3. Modify the teach data.
4. Replace the servo board.
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Error code
: E1341
Error message : [MCXX]Regenerative resistor overheat.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Either or all of the thermal switches are disconnected in the regenerative resistor (140 °C) or in
the regenerative resistor of the optional additional regenerative resistor (140 °C). Because each
thermal switch is serially connected, the AS software cannot detect which thermal switch is
disconnected.
MC unit
MC control board
CPU
MC power board
Regeneration
overheat error
Regenerative
circuit
Regenerative
resistor
Additional
regenerative
resistor
Thermal
(140°C)
Thermal
(140°C)
Additional
regeneration unit
(option)
Main cause:
1. Insufficient cooling activated the thermal switch, caused by halt or defect in the regenerative
resistor cooling fan, cooling fan for additional regenerative resistor(option).
2. Inappropriate teaching exceeding regenerative capacity was executed.
3. Ambient temperature of the controller is high.
4. Disconnection or defective connection in the harness between X354 and XRS in the MC power
board.
5. Disconnection or defective connection in the harness between the MC power board and
additional regenerative resistor.
6. Defect in the MC power board.
7. Defect in the MC control board.
8. Defect in the regenerative resistor or in the additional regenerative resistor.
9. Defect in the servo board.
Countermeasure:
1. Check if the cooling fans are functioning properly.
2. Modify the teach data, or reduce repeat speed.
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3. Reduce the ambient temperature of the controller.
4. Check for disconnection or short-circuit in each harness.
5. Replace the MC unit.
6. Replace the regenerative resistor, or additional regenerative resistor (option).
7. Replace the servo board.
！
CAUTION
Do not turn OFF the controller power immediately after ending the
operation. Especially, for the controller applied with regenerative
resistor, set fan control for more than 60 minutes and leave the
controller power ON until the resistor is cooled-down enough.
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Error code
: E1342
Error message : Motor harness disconnected or robot temperature exceeded limit.(MCXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The thermal contact in the arm connected to the motor harness activated or the harness was
disconnected.
Upper arm
Thermal
switch
MC unit
MC control board
Thermal line
(TH)
Rotor trunk
Thermal
switch
Robot arm
Controller
Main cause:
1. Disconnection of thermal line in the arm.
2. Disconnection or defective connection in the separate harness.
3. Disconnection of the X314 harness in the MC control board.
4. Abnormal brake power supply (DC26 V).
5. Defect in the MC control board.
6. When the thermal switch is built-in:
(1) An error such as overload has just occurred.
(2) The robot load has exceeded the payload.
(3) The ambient temperature of the robot exceeded the allowable range for the robot operation.
(4) Excessive robot motion such as repeated shuttle motion (counter teach) was executed.
(5) Servoing was continued for a long time at a posture applying force load on the arm.
(6) Defect in the thermal switch.
Countermeasure:
1. Check the thermal line between X314 connector in the MC unit and the arm.
2. Replace the MC control board.
3. Refer to “E1337” if the brake power supply has any abnormalities.
4. Check the operation conditions and use the robot within its specified ratings.
5. When the servoing continues for a long time at a posture applying force load on the arm, which
results in a line stop, set the robot to HOLD by interlock, etc. or set an Auto servo OFF time in
Aux. function 0808 Environment Data.
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Error code
: E1343
Error message : Mismatch betw connected place of brake harness and software setting. (JtXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The external axis setting in the software (which specifies that in which MC unit is used for each
brake for 7, 8, 9 axes) and the connection place of brake harness for external axis do not match.
Main cause:
1. Incorrect setting for external axis in the software.
2. Disconnection or defective connection in the harness of X317, X318, or X319.
3. Defect in the MC control board.
Countermeasure:
1. Check the software setting in Aux. function <2002 External axis setting>.
2. Check the connection in the harness of X317, X318, and X319 in the MC unit.
3. Replace the MC control board.
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Error code
: E1344
Error message : JtXX Current sendor is disconnected or out of order.(V)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The V-phase motor current detection circuit is defective in the power block board, or the signal
line to the servo board is abnormal.
Main cause:
1. Defect in the power block board.
2. Defect in the servo board.
3. Defective connection in the harness between the power block board and servo board.
Countermeasure:
1. Check the connector connection in the harness between the power block board and servo
board.
2. Replace the servo amplifier unit.
Servo FPGA
Current feedback
Servo board
PWM
Current
detection
circuit
IPM
Each motor
Robot main body
Power block
Controller
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Error code
: E1345
Error message : [Servo boardXX]Limit switch signal line is disconnected.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The axis restriction limit switch was activated although the robot did not move beyond the set
motion range (restricted space).
Set the motion range of each axis in Aux. function 0507 Motion Limits. Normally, the
maximum motion range of the robot is set at factory shipment.
To change the setting of the motion range, take into consideration the following conditions.
Maximum
operating
range
>
Mechanical
stopper
>
Axis restriction
>
limit switch
Set motion range
(restricted space)
The mechanical stopper and the axis restriction limit switch are options, and the axis in which
they are installed varies with machine model and configuration. Typically, the AS software
restricts robot motion so as not to exceed the set motion range.
Axis
restriction
LS
Axis
restriction
LS
FPGA
Encoder battery backup board
Servo board
Controller
Robot arm
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Main cause:
1. The axis restriction limit switch was activated because the motion range of the robot is set
wider than the placement of the axis restriction limit switches.
2. Due to an incorrect setting of the zeroing data causing unexpected motion of the robot, etc., the
axis restriction limit switch was activated.
3. Disconnection or defect in the axis restriction limit switch harness.
4. Defect in the axis restriction limit switch.
5. Defect in the servo board.
Countermeasure:
1. When this error occurs, the motor power can be turned ON while pressing and holding down
the override switch on the power sequence board. Move the arm in teach mode into the
motion range.
2. Or, use the manual brake release switch (option) and release the brake manually to move the
arm into the motion range when power cannot be turned ON. At this time, turn OFF motor
power and release all Emergency Stops without fail.
3. Set the motion range to an appropriate value.
4. Change placement of the axis restriction limit switches appropriately.
5. Check the harness or the axis restriction limit switch, and replace them if necessary.
6. Replace the servo board.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1> → <DIAG Monitor> →
<Safe_Cir Monitor2(safety circuit input monitor2)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
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Error code
: E1347
Error message : [MCXX]Destination spec is incorrect.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
MC unit for Japan spec. is used for Europe/North America spec. controllers.
Main cause:
1. Incorrect part number of the MC unit is used.
2. Defect in the MC unit.
3. Disconnection in the harness (X206-X502) between the mother board and servo board.
4. Defect in the power sequence board.
Countermeasure:
1. Check the part number for the MC unit.
2. Replace the MC unit.
3. Check the harness (X206-X502) between the mother board and servo board.
4. Replace the power sequence board.
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Error code
: E1348
Error message : [MCXX]Robot arm spec/separate control spec is incorrect. (Servo boardXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Incorrect MC unit is used. The first MC unit should be used for robot main body, and the
second or later should be used for separation operation.
Main cause:
1. The MC unit for robot main body is connected as a MC unit for separation operation. Or the
MC unit for separation operation is connected as a MC unit for robot main body.
2. Defect in the MC control board.
Countermeasure:
1. Check if the MC unit part number and the destination of the connection are correct.
2. Replace the MC unit.
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Error code
: E1349
Error message : [MCXX]Explosion proof setting is mismatch.(Servo boardXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
Specifications of AS software and MC unit do not match in point of non-explosion-proof or
explosion-proof specification.
Main cause:
1. The AS software version does not correspond to the MC unit.
2. Defect in the MC control board.
Countermeasure:
1. Check if the AS software version which is in use is correct.
2. Check the MC unit part number and replace the MC unit if incorrect.
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Error code
: E1350
Error message : [MCXX]MC specification error.[CodeXX](Servo boardXX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The MC unit ID does not correspond to any specifications of the MC unit.
Main cause:
Defect in the MC unit.
Countermeasure:
Replace the MC unit.
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Error code
: E1352
Error message : JtXX Codes set in software and power block do not match.
Error processing : Controller power OFF
Error reset : Non-acceptable
Content:
The power block setting does not match between the hardware and software.
Main cause:
1. Incorrect servo amp. unit part number is used in the software model and motor settings.
2. Defect in the power block board.
3. Defect in the servo board.
Countermeasures:
1. Check the servo amp. unit part number for the software model and motor settings in Aux. <804
Software version>, <2002 External axis setting>.
2. Replace the servo amp. unit.
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Error code
: E1353
Error message : [Main CPU board]CPU temperature is abnormal.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The CPU temperature exceeded the motion limit temperature in the main CPU board.
Main cause:
1. High ambient temperature.
2. Malfunction of the cooling fan.
3. Defect in the main CPU board.
Countermeasure:
1. Lower the ambient temperature.
2. Check the cooling devices such as cooling fan, etc.
3. Replace the main CPU board.
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Error code
: E1355
Error message : Error in servo I/F command communication.(Code:XX)
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
An error occurred in the communication (command communication) with the servo board. The
every two digits of the code starting from the left stands for unit number, command number,
channel number, and error code.
Main cause:
1. Servo group software that does not correspond to AS group software is installed.
2. Defect in the main CPU board.
3. Defect in the servo board.
4. Defect in the mother board.
Countermeasure:
1. Reset the error. If it cannot be reset, turn the controller power OFF and then ON. If a
message for initialization appears, select <NO>.
2. Check the servo group software version, then reinstall the software.
3. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
4. If reproducibility cannot be confirmed or the program does not return to normal, replace the
main CPU board, servo board, mother board.
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Error code
: E1359
Error message : JtXX axis U phase overcurrent.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
A large direct current may flow into one phase out of three phases in the motors depending on
robot arm posture. If the state continues, electric lines may be burned out even though the motor
overload does not occur.
Servo board
Motor current
Servo
FPGA
Servo
CPU
Abnormal
Current
feedback
Continuous
rating current
Time
Overload curve
IPM
Current
detection
circuit
U,V,W earth
Each
motor
Robot main body
Power block
Main cause:
The period during which the robot maintains the robot arm posture with servo ON is too long.
Countermeasure:
1. Modify the teaching so that the load on the axis where the error occurred decreases. (Avoid a
teaching that causes large load, such as one applied by maintaining the arm posture
horizontally holding a workpiece.)
2. If the posture maintaining period becomes long, execute servo OFF or enable auto servo OFF
function.
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Error code
: E1360
Error message : JtXX axis V phase overcurrent.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
A large direct current may flow into one phase out of three phases in the motors depending on the
robot arm posture. If the state continues, electric lines may be burned out even though the motor
overload does not occur.
Servo board
Motor current
Servo
FPGA
Servo
CPU
Abnormal
Current
feedback
Continuous
rating current
Time
Overload curve
IPM
Current
detection
circuit
U,V,W earth
Each
motor
Robot main body
Power block
Main cause:
The period during which the robot maintains the robot arm posture with servo ON is too long.
Countermeasure:
1. Modify the teaching so that the load on the axis where the error occurred decreases. (Avoid a
teaching that causes large load, such as one applied by maintaining the arm posture
horizontally holding a workpiece.)
2. If the posture maintaining period becomes long, execute servo OFF or enable auto servo OFF
function.
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Error code
: E1361
Error message : JtXX axis W phase overcurrent.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
A large direct current may flow into one phase out of three phases in the motors depending on the
robot arm posture. If the state continues, electric lines may be burned out even though the motor
overload does not occur.
Servo board
Motor current
Servo
FPGA
Servo
CPU
Abnormal
Current
feedback
Continuous
rating current
Time
Overload curve
IPM
Current
detection
circuit
U,V,W earth
Each
motor
Robot main body
Power block
Main cause:
The period during which the robot maintains the robot arm posture with servo ON is too long.
Countermeasure:
1. Modify the teaching so that the load on the axis where the error occurred decreases. (Avoid a
teaching that causes large load, such as one applied by maintaining the arm posture
horizontally holding a workpiece.)
2. If the posture maintaining period becomes long, execute servo OFF or enable auto servo OFF
function.
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Error code
: E1362
Error message : [Servo boardXX]Speed of tool center point exceeded safety speed.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The servo software detected that the tool point speed exceeded the safety speed (250 mm/s)
during operation in teach mode or in check mode.
Main cause:
1. The tool point speed exceeded the safety speed due to speed overshoot caused by excessive
acceleration/deceleration.
2. The tool point speed error was detected prior to each axis speed error (E1123) or together with
E1123.
Countermeasure:
1. For each axis speed error, refer to countermeasure for E1123.
2. Execute error reset.
3. If the same error occurs, lessen manual speed setting. Or modify the data to smaller value in
speed in Aux. <401 Teach/Check Speed>.
4. When operating with peripheral equipment cooperatively such as conveyor synchronization
option, decrease the speed for the peripheral equipment.
5. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: E1363
Error message : [Servo boardXX]Speed of flange center point exceeded safety speed.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The servo software detected that the flange center speed exceeded the safety speed (250 mm/s)
during operation in teach mode or in check mode.
Main cause:
1. The flange center speed exceeded the safety speed due to speed overshoot caused by excessive
acceleration/deceleration.
2. The tool point speed error was detected prior to each axis speed error (E1123) or together with
E1123.
Countermeasure:
1. For each axis speed error, refer to countermeasure for E1123.
2. Execute error reset.
3. If the same error occurs, lessen manual speed setting. Or modify the data to smaller value in
speed in Aux. <401 Teach/Check Speed>.
4. When operating with peripheral equipment cooperatively such as conveyor synchronization
option, decrease the speed for the peripheral equipment.
5. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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Error code
: E1366
Error message : Watchdog error in NoXX ANYBUS interface board.
Error processing : Motor power OFF
Error reset : Non-acceptable
Content:
The bus access from the main CPU board to ANYBUS interface was not made for a certain
period of time (250 ms) or more.
Main cause:
1. Defect in the main CPU board.
2. Defect in the ANYBUS interface board.
3. Defect in the mother board.
Countermeasure:
1. Turn the AC primary power OFF and then ON, and check if the same error occurs.
2. Replace the main CPU board.
3. Replace the ANYBUS interface board.
4. Replace the mother board.
5. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
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3. Troubleshooting
Error code
: E4074
Error message : [Servo boardXX]No response from MCXX.(Code:XX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
This error occurs when no response is received from the MC unit.
Main cause:
1. Disconnection or defective connection in the harness between the MC unit (X304) and servo
board (X503, X504, X505).
2. Defect in the MC unit.
3. Defect in the servo board.
Countermeasure:
1. Check the harness between the MC unit and servo board.
2. Replace the MC unit.
3. Replace the servo board.
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3. Troubleshooting
Error code
: E4075
Error message : [Servo boardXX]Error in communication with MCXX.(Code:XX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
An abnormality is detected on the servo board side in the communication between the servo
board and MC unit.
Main cause:
1. Defect in the MC unit (MC control board).
2. Defect in the servo board.
3. Defective wiring between the servo board and MC unit.
Countermeasure:
1. Check if the error is resolved by executing error reset.
2. Replace the MC control board.
3. Replace the servo board.
4. Check the wiring between servo board (X503 for MC unit 1, X504 for MC unit 2, X505 for
MC unit 3) and MC unit (X304).
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3. Troubleshooting
Error code
: E4076
Error message : [MCXX]Servo boardXX communication error.(Code:XX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Communication between the servo board and MC unit is not performed properly.
Main cause:
1. Defect in the servo board.
2. Defect in the MC control board.
3. Disconnection or defective connection in the harness between the servo board and MC unit.
Countermeasure:
1. Check the connection between the servo board and MC unit.
2. Replace the MC unit.
3. Replace the servo board.
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3. Troubleshooting
Error code
: E4077
Error message : [Servo boardXX]Error in communication with main CPU board.(Code:XX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Data communication between the main CPU board and servo board failed three times or more in
a row.
Main cause:
<Code>
0,1,8,9,A: Data processing is abnormal in the servo board due to defective servo board.
2
: Communication data is not received from the main CPU board due to disconnection of
the communication line.
3
: Bit error in the communication data from the main CPU board due to defective
connection of the communication line.
4,5,6,7 : Abnormal data due to defective main CPU board or defective servo board.
Countermeasure:
Execute error reset. If the error cannot be solved after executing error reset, the cause is possibly
in the servo board, main CPU board, or communication line between boards. In this case, report
the error code to KHI.
<Code>
0,1,8,9,A: Replace the servo board.
2
: Check for unconnected connector or disconnection in the communication line
between the main CPU board and servo board.
3
: Check if the communication line between the main CPU board and servo board is
connected properly.
4,5,6,7 : Replace the main CPU board or servo board.
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3. Troubleshooting
Error code
Error message
: E4078
: [Servo boardXX]Error in command communication with the main CPU
board.(Code:XX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
In command communication between the main CPU board and servo board, the number that the
same data is sent from the servo board became five times or more.
Main cause:
<Code>
0
: The number of data resendings is abnormal due to no response from the main CPU board.
The cause may be in the abnormal communication check that is not performed constantly
between the main CPU board and servo board.
1
: The number of data resendings is abnormal in the main CPU board because the data that
sent from the servo board is not read normally. The cause may be in the defective servo
board.
Countermeasure:
1. Execute error reset.
2. If the error occurs frequently, replace the main CPU board or servo board.
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3. Troubleshooting
Error code
: E6506
Error message : Torch interference.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The limit switch built in the torch holder of the arc welding specification robot detected torch
interference.
Main cause:
1. The torch interfered with an object, and the limit switch in the torch bracket functioned.
2. Disconnection in the harness of the limit switch.
Countermeasure:
1. After error reset, move the robot in teach mode and return the torch to its original state.
2. Check the harness for the limit switch, and replace it if necessary.
After error reset, the robot can be moved in teach mode. In repeat mode, the torch cannot be
returned to its original state.
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3. Troubleshooting
Error code
: W1012
Error message : Servo parameter changed. Turn OFF & ON the control power.
Error processing : Display
Error reset : Acceptable
Content:
In the following cases, turning controller power OFF then ON is required for writing new data in
the servo board:
- loading of robot/system data that enables use of optional axes (Jt7+)
- setting of the servo parameter data or model for external axes
- changing the number of corresponding axes.
Countermeasure:
Turn the controller power OFF, and then ON.
[NOTE]
When the model is changed, the servo group software must
also be replaced with the correct one so that normal
operations can be supported.
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3. Troubleshooting
Error code
: W1013
Error message : Encoder battery low voltage. [Servo(XX)]
Error processing : Display
Error reset : Acceptable
Content:
The battery voltage which is built-in the base part of the robot arm and is connected to the
encoder battery backup board, etc. has decreased to +3.3 V or less. Or, the encoder battery
alarm harness has been disconnected. This error is only detected when controller power and
motor power are turned ON.
Encoder
Servo
CPU
Encoder
I/F
Servo board
Encoder
Battery alarm signal
Encoder power
supply +12 V
Power supply
circuit/
Battery voltage
detect. circuit
Battery
Encoder battery backup board
Robot main body
Controller
Main cause:
1. Deterioration of the battery.
2. Defect in the encoder battery backup board.
3. Battery consumption increased due to a defect in the encoder, or a short-circuit in the harness
between the encoder battery backup board and encoder, thereby the battery discharged.
4. Battery alarm signal line from the encoder battery backup board is disconnected.
5. Defect in the servo board, etc.
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3. Troubleshooting
Countermeasure:
1. The internal data of the encoder may not be maintained when this error occurs. Therefore,
confirm without fail that the angle values are at 0 after matching all axes to their scribe marks
(mechanical zero point) in teach mode. If angle values are not 0, do not fail to execute
zeroing.
！
WARNING
1. After the error reset, automatic operation is possible. However,
beware there is a high possibility of causing malposition of the robot
as the current value goes out of order. Do not fail to confirm the
above-mentioned zeroing and the playback of steps in check mode.
2. When this error occurs, beware that the internal data of the encoder
may not be maintained if turning OFF the controller power.
2. When the battery for the encoder backup decreases to +3.3 V or less, replace the battery
promptly. Replace the encoder batteries used in all axes, including conveyor, at the same
time.
3. Check for disconnection or short-circuit in each harness.
4. Replace the encoder, servo board, or encoder battery backup board.
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3. Troubleshooting
Error code
: W1017
Error message : Encoder battery low voltage.[External axis(XX)]
Error processing : Display
Error reset : Acceptable
Content:
The battery voltage which is built-in the encoder relay box for external axis, etc. and is connected
to the encoder battery backup board, etc. has decreased to +3.3 V or less. Or, the encoder
battery alarm harness has been disconnected. Take note that this error is only detected when
controller power and motor power are turned ON.
Encoder
Servo
CPU
Encoder
I/F
Servo board
Encoder
Battery alarm signal
Encoder power
supply +12 V
Power supply
circuit/
Battery voltage
detect. circuit
Battery
Encoder battery backup board
Encoder box for external axis
Controller
Main cause:
1. Deterioration of the battery.
2. Defect in the encoder battery backup board.
3. Battery consumption increased due to a defect in the encoder, or a short-circuit in the harness
between the encoder battery backup board and encoder, thereby discharging the battery.
4. Battery alarm signal line from the encoder battery backup board is disconnected.
5. Defect in the servo board, etc.
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3. Troubleshooting
Countermeasure:
1. The internal data of the encoder may not be maintained when this error occurs. Therefore,
confirm without fail that the angle values are at 0 after matching all axes to the mechanical
zero points in teach mode. If angle values are not 0, do not fail to execute zeroing.
！
WARNING
1. After the error reset, automatic operation is possible. However,
beware there is a high possibility of causing malposition of the robot
as the current value goes out of order. Do not fail to confirm the
above-mentioned zeroing and the playback of steps in check mode.
2. When this error occurs, beware that the internal data of the encoder
may not be maintained if turning OFF the controller power.
2. When the battery for the encoder backup decreases to +3.3 V or less, replace the battery
promptly. Replace the encoder batteries used in all axes, including conveyor, at the same
time.
3. Check for disconnection or short-circuit of each harness.
4. Replace the encoder, encoder battery backup board.
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3. Troubleshooting
Error code
: W1053
Error message : (FANXX-XX)Rotational speed of fan is below the limit. (ServoBoardXX)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
Rotation speed of fan inside the controller has decreased.
Main cause:
1. Deterioration of the fan.
2. Disconnection or defective connection in the harness between the fan and MC unit.
3. Defect in the MC control board.
4. Abnormal brake power supply inside the MC unit.
Countermeasure:
1. Check if the harness between the fan and MC unit is connected properly.
2. Replace the fan.
3. Replace the MC unit.
NOTE “XX-XX” of (FANXX-XX) in the error message stands for MC unit and fan numbers,
and abnormal fan can be specified from these numbers. As for the place where the fan
is mounted, refer to drawings of “Locations and numbers of fans” in “4.5.4 Fan inside
MC Unit”.
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Error code
: W1054
Error message : AVR reaches the expected lifetime soon.
Error processing : Motor power OFF
Error reset : Acceptable
Content:
The residual lifetime of the AVR has become short, which is predicted by the function that
detects temperature and residual life time of the AVR.
Main cause:
1. The residual lifetime of the AVR has become less than 1/8 of the expected lifetime.
2. Abnormality occurred in the power sequence board.
Countermeasure:
1. Replace the AVR.
2. Replace the power sequence board.
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Error code
: W1056
Error message : [Main CPU board]CPU temperature exceeded the limit. (XX 1/1000 deg C)
Error processing : Motor power OFF
Error reset : Acceptable
Content:
In the main CPU board, CPU temperature has increased and reached the point that may damage
the CPU if it kept operating.
Main cause:
1. High ambient temperature.
2. Malfunction of the cooling fan.
3. Defect in the main CPU board.
Countermeasure:
1. Lower the ambient temperature.
2. Check the cooling devices such as cooling fan, etc.
3. Replace the main CPU board.
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MEMO
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4.0
4. Procedures for Replacement
PROCEDURES FOR REPLACEMENT
This chapter describes procedures for replacement of parts inside the controller: printed
boards, servo amplifiers, hardware including AVR, etc., and, units.
4.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.3
4.3.1
4.3.2
4.3.3
4.4
4.4.1
4.4.2
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.6
4.6.1
4.6.2
4.7
4.7.1
General Safety Precautions on Replacement ･････････････････････････････････ 4-2
Parts in Card Rack ････････････････････････････････････････････････････････ 4-5
1TA Board (Main CPU Board) ･････････････････････････････････････････････ 4-5
CF card on 1TA Board (Main CPU Board) ･･････････････････････････････････ 4-6
1TR Board (Power Sequence Board)････････････････････････････････････････ 4-8
AVR･････････････････････････････････････････････････････････････････････ 4-8
Servo Amplifier Unit for 6 Axes Part･･･････････････････････････････････････ 4-10
Servo Amplifier Unit for 6 Axes ･･･････････････････････････････････････････ 4-10
1TB Board (Servo Board) ････････････････････････････････････････････････ 4-12
Amplifier Unit for Single Axis ････････････････････････････････････････････ 4-14
MC Unit Part････････････････････････････････････････････････････････････ 4-15
MC Unit ････････････････････････････････････････････････････････････････ 4-15
1TQ/1TV Boards (MC Control Board) ･････････････････････････････････････ 4-16
Fans ････････････････････････････････････････････････････････････････････ 4-18
Fans for Card Rack ･･････････････････････････････････････････････････････ 4-18
Fans for Servo Amp. Unit for 6 Axes･･･････････････････････････････････････ 4-18
Fan for Amp. Unit for Single Axis ･････････････････････････････････････････ 4-19
Fan inside MC Unit ･･････････････････････････････････････････････････････ 4-19
Batteries ････････････････････････････････････････････････････････････････ 4-21
Coin Battery on 1TA Board ･･･････････････････････････････････････････････ 4-21
Battery on 1FG/1HG Board ･･･････････････････････････････････････････････ 4-22
Fuses ･･･････････････････････････････････････････････････････････････････ 4-23
Fuses on 1TR Board ･････････････････････････････････････････････････････ 4-23
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4.1
4. Procedures for Replacement
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 these,
adhere the safety measures required for each replacement procedure.
！
CAUTION
Parts replacement duties are limited to personnel who have
completed special training and education for the installed
robot or for an equivalent model.
1. Read and understand thoroughly all manuals, specifications and related documents
provided by Kawasaki before operation.
2. Before entering the safety fence (safeguarded space), make sure all necessary safety
measures are prepared and functioning well.
3. Before starting replacement work, shut OFF controller power up to the external power
switch. Display signs indicating clearly “POWER CUT-OFF IN PROGRESS” or
“REPLACEMENT IN PROGRESS”, and lock out/tag out the external power switch to
prevent personnel from accidentally turning ON the power.
4. Before starting replacement work, secure enough space around the robot so there is no
danger of interference with peripheral systems. Shut down the peripheral systems
completely so they will not make any sudden motion.
5. Disable automatic operation functions when entering the safety fence. If the robot
makes any abnormal motion, press EMERGENCY STOP switch immediately, and
evacuate on a planned path of retreat.
6. In addition to the EMERGENCY STOP switch operated by the technician, install another
E-STOP switch for the supervisor outside the safety fence, in a place where the robot’s
entire motion range can be monitored and the switch is accessible and easy for the
supervisor to press. If the robot moves abnormally during observation of the
replacement, press the E-STOP switch immediately. After an E-Stop, reset and restart
robot operations from outside the fence. Moreover, monitoring duties are limited to
personnel who are trained and qualified.
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4. Procedures for Replacement
7. Use only Kawasaki approved parts during replacement.
8. When replacing printed boards, do not fail to turn OFF controller power. To replace
servo amplifier, MC unit, or AVR, wait at least three minutes after controller power OFF
before disconnecting connectors. Then confirm that output voltage from the DC power
supply and the P-N voltage are 0 V.
9. During operation, both technician and supervisor must always watch out for abnormal
motion and possible pinch points in and around the robot.
10. Semiconductors are often used in printed boards. Note that these semiconductors are
sensitive to static electricity, be sure to discharge any electrostatic on the body before
handling the printed boards.
11. Directly touching the parts containing semiconductors may cause electrostatic discharge
damage. When handling printed boards, do not touch the semiconductors directly but
hold the periphery of the printed boards. If parts must be touched directly, confirm that
electrostatic on the body has been discharged.
12. Putting printed boards directly onto the controller, etc. may cause electrostatic discharge
damage. Be sure to put them on an electrostatic-proof mat board or sheet, or enclose
printed boards in an electrostatic-proof bag.
13. Avoid removing printed boards at controller power ON, or turning the controller power
ON without any printed boards mounted.
14. Take a record of all data set currently on controller, printed boards, etc. so the system can
be restored to its normal operating condition.
15. To prevent position deviation of the robot, take a record of the robot’s pose before
starting the replacement procedure.
16. Be sure to connect connectors and cables correctly. When using connectors equipped
with locks, do not fail to lock after insertion. Do not touch connector pins.
17. Immediately after robot motion stop, the heat sink, the regenerative resistor, etc. may be
very hot. Do not touch the servo amplifier unit directly, there is a danger of burn.
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Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
18. Printed boards and servo amplifiers are designed differently for each robot model.
sure to replace the correct type.
Be
19. When air or water is supplied, shut OFF the supply source and release any remaining
pressure from the lines before starting any replacement procedure.
20. Use lighting of 1500 lux or more to avoid mistakes when reading data or replacing
defective parts.
21. After completion of replacement, confirm that the controller functions with no
abnormality.
4-4
E Series Controller
Kawasaki Robot Troubleshooting Manual
4.2
4. Procedures for Replacement
PARTS IN CARD RACK
In the card rack of E controller, AVR, 1TA board (main CPU board), 1TR board (power
sequence board), and 1TW board (IO board, option) are housed from the left as shown below.
This section describes the replacement procedure for the parts inside the card rack.
1TA board
1TR board
1TW board (option)
AVR
Card rack front
4.2.1
1TA BOARD (MAIN CPU BOARD)
1. This is the main CPU board used for storing taught pose data, user program data, etc. in
the CF card. Before replacing the board, save all data to storage media such as USB
memory, etc. just in case. For more details about data saving procedure, refer to the
Operation Manual, a separate volume.
2. After completion of data saving, turn OFF the controller power.
3. Disconnect all the connectors with cables connected to the board.
4. Loosen the screws at the top and bottom of ejectors of the 1TA board, and pull out the
board from the card rack by holding the ejectors at both ends of the board.
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Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
5. When replacing only the 1TA board, demount the CF card. (Demount the CF card
without touching any other electronic parts on the 1TA board.)
6. Confirm that settings for DIP SW on the new 1TA are the same as settings before board
replacement. For the CF card demounted in step 5, insert it to the new 1TA.
7. Remount the new 1TA board into the card rack and set it in the mother board securely.
8. Tighten the screws at the top and bottom of ejectors of the 1TA board.
9. Reconnect all the connectors with cables.
4.2.2
CF CARD ON 1TA BOARD (MAIN CPU BOARD)
1. The CF card on the 1TA board stores each software and taught program data, etc.
Before replacing the CF card, be sure to save all data to storage media such as USB
memory, etc. For more details about data saving procedures, refer to the Operation
Manual.
2. After completion of data saving, turn OFF the controller power.
3. Dismount the 1TA board from the card rack by following the procedure described in 4.2.1
1TA board.
4. Remove the CF card from the 1TA board without touching any other electronic parts on
the 1TA.
5. Insert a new CF card in the right direction into the 1TA board.
6. Remount the 1TA board into the card rack and set it in the mother board securely.
7. Reconnect all the harnesses, then tighten the screws at top and bottom of the 1TA board.
8. Insert a USB memory containing new software into the USB port in the accessory panel,
and supply controller power by switching the DIP SW 3, 5, 8 on the 1TA board to ON.
9. Software download automatically starts. When the download is complete, cut OFF the
controller power, then switch the DIP SW 8 on the 1TA board to ON.
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Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
10. Supply controller power and when the confirmation query for initialization is displayed,
select <999: Initialization of all data>.
11. When the confirmation query for initialization is displayed again, select <1: YES>.
12. After completion of initialization, load all data saved before board replacement into the
1TA board. For more details about data loading procedure, refer to the Operation
Manual.
13. Turn OFF the controller power.
14. Switch the DIP SW 8 on the 1TA board to OFF.
Ejector
Screw
Ejector
Screw
DIP SW
CF card
Outline view of 1TA board
4-7
E Series Controller
Kawasaki Robot Troubleshooting Manual
4.2.3
4. Procedures for Replacement
1TR BOARD (POWER SEQUENCE BOARD)
1. Turn OFF the controller power.
2. Loosen the screws at the top and bottom of the 1TR board, and pull out the 1TR from the
card rack by holding the ejectors at both ends of the board. If cables are connected to the
front connector, disconnect them first.
3. Confirm that settings for SW2, JP1 and JP2 on the new 1TR are the same as settings before
board replacement. Then, remount the new 1TR to the card rack and set it in the mother
board securely.
4. Tighten the screws at the top and bottom of the 1TR board. When cables are
disconnected from the front connector in step 2, reconnect them.
Ejector
Ejector
Screw
Screw
JP1
JP2
SW2
Outline view of 1TR board
4.2.4
AVR
1. Turn OFF the controller power.
2. Disconnect the connectors connected to the AVR.
3. Loosen the two screws fixing the AVR, and remove the AVR.
4. Insert a new AVR to the card rack, and tighten it with two screws securely.
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E Series Controller
Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
5. Reconnect the connectors disconnected in step 2 and turn ON the controller power.
6. Confirm that the voltage between respective check pins on the 1TR board is within the
range shown in the table below.
No.
Color
TP1
Red
TP2 Yellow
TP3 Orange
TP5 White
Standard
Allowable range
+5.0 V
If the voltage is out of
allowable range,
adjust the voltage with
adjusting knob on the AVR.
adjust the voltage with
+3.25 V - +3.35 V
adjusting knob on the AVR.
+12.25 V replace the AVR.
+12.75 V
TP4 (black)
+23.9 V - +24.7 V replace the AVR.
TP6 (brown)
+5.05 V - +5.15 V
+3.3 V
+12.0 V
+24 V
GND
TP4 (black)
TP4 (black)
7. If there is no abnormality in the controller after checking voltage, paint-lock each adjusting
knob of the AVR.
Screw
Connector
AVR
+5 V adjust.
+3.3 V adjust.
Voltage adjusting knob
Screw
Adjusting knob
(Enlarged view)
Outline view of AVR
4-9
E Series Controller
Kawasaki Robot Troubleshooting Manual
4.3
4. Procedures for Replacement
SERVO AMPLIFIER UNIT FOR 6 AXES PART
This section describes the procedure for replacement of the servo amplifier unit mounted in
the controller. Since there are several kinds of servo amplifier unit for 6 axes depending on
robot models, be sure to use appropriate unit for the robot when replacing it.
！
DANGER
Do not touch any connector pins during replacement because
high voltage may be applied in the power block unit.
4.3.1
SERVO AMPLIFIER UNIT FOR 6 AXES
！
DANGER
Before starting replacement work, turn OFF the controller
power and wait at least three minutes.
！
CAUTION
Power block unit weighs approx. 10 kg. Be careful not to
incur back injury, etc. when removing the power block unit.
1. Disconnect all connectors connected to the servo amplifier unit. (Also disconnect
connectors connected to the servo board, and connectors X352, X358 in the right back of
the MC unit.)
2. Loosen the two upper screws fixing the servo amplifier unit to the controller until the unit
can be come free from the controller. (These screws are not removed from the servo
amplifier unit.)
3. Unscrew the ground line fixing screw at the upper left of the servo amplifier unit for 6 axes
and disconnect the line. (Be careful of the fall of the screw as it is removable.)
4. Unlock the two bottom levers fixing the servo amplifier unit to the controller. (Slide both
levers inward to unlock.)
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Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
5. Remove the servo amplifier unit by pulling it out sliding on the support platform.
safe, hold the handle on top the unit with one hand.
To be
6. Place a new unit on the support platform, and set it into the controller by holding the
handle on top with one hand. Then, mount it by tightening the two upper screws and
locking two bottom levers securely. (Slide both levers outward to lock.) Fix the ground
line with fixing screw at the upper left of the unit too.
7. Reconnect all the connectors disconnected in step 1.
Servo amp. unit fixing screws (two at upper）
Ground line
fixing screw
Servo amp. unit fixing levers (two at bottom）
(e.g.: E2x controller)
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E Series Controller
Kawasaki Robot Troubleshooting Manual
4.3.2
4. Procedures for Replacement
1TB BOARD (SERVO BOARD)
This section describes the procedure for replacement of the 1TB board (servo board) mounted
in the servo amplifier unit for 6 axes.
1. Dismount the servo amp. unit for 6 axes from the controller by following the procedure
shown in “4.3.1 servo amplifier unit for 6 axes”.
2. Uncover the servo amp. front cover (plastic) that is hooked at right, left and bottom of the
unit.
Push here.
Push here.
1. Unhook the hooked
parts at right
and left.
2. Unhook the two
hooked parts to remove
the cover.
Servo amp. unit for 6 axes front
Left side view
3. When replacing the 1TB board, take out it together with fixing plates that is connected
with the board. Unscrew 6 plate fixing screws shown in the figure below.*
NOTE* Do not remove only the 1TB board from the servo amplifier unit. Doing so
applies excessive load on the board and may damage it, causing bend, etc.
4. Pull out the plate with 1TB board and dismount it from the power block unit by holding the
handle hole at the bottom and the plate edge at the top of the plate. (1TB board is
connected with the power block unit via rear connectors.)
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E Series Controller
Kawasaki Robot Troubleshooting Manual
Plate edge
4. Procedures for Replacement
Screw
Right side view
1TB board
Connector
Screw
Connector
Screw
Connector
1TB board
Screw
Handle hole
Power block
1TB board fixing plate
5. Unscrew the nine screws fixing the 1TB board and its plate, and remove the 1TB board.
Screw
Screw
ネジ
Screw
Screw
Screw
Screw
6. Fix a new 1TB board with nine screws to the plate.
7. Remount the plate with the 1TB board to the power block unit in the reverse order of step 4.
Position the plate and connect the six rear connectors to the power block securely. (The
connectors can be easily connected by pressing the place where PUSH is printed on the
1TB board.)
8. Fix the plate and power block unit with the six screws unscrewed in step 3.
9. Re-cover the servo amp. front cover. (Hook from the bottom side to mount.)
10.Remount the servo amp. unit for 6 axes in accordance with the procedure of “4.3.1 Servo
Amplifier Unit for 6 Axes”.
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E Series Controller
Kawasaki Robot Troubleshooting Manual
4.3.3
4. Procedures for Replacement
AMPLIFIER UNIT FOR SINGLE AXIS
There are several kinds of amplifier unit for single axis depending on robot models.
to use appropriate unit for the robot when replacing it.
Be sure
！ DANGER
Before starting replacement work, turn OFF the
controller power and wait at least three minutes.
1. Disconnect all connectors connected to the amplifier unit.
2. Loosen the four screws (1 to 4 in figure below) fixing the amplifier unit to the controller by
supporting the unit* until the amplifier unit can be come free from the controller. (These
screws are not removed from the amplifier unit.)
NOTE* The unit may fall if it is not supported.
3. Remove the amplifier unit.
4. Mount a new unit to the controller with the four screws loosened in step 2 securely.
5. Reconnect the connectors disconnected in step 1.
1
2
X566
X563
X564
X562
X565
X551
3
4
Amplifier unit for single axis
(e.g.: E2x controller)
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E Series Controller
Kawasaki Robot Troubleshooting Manual
4.4
4. Procedures for Replacement
MC UNIT PART
This section describes the procedure for replacement of the MC unit and the 1TQ/1TV boards
(MC control boards) which are mounted in the MC unit.
4.4.1
MC UNIT
！ DANGER
Before starting replacement work, turn OFF the
controller power and wait at least three minutes.
1. Disconnect all connectors connected to the MC unit.
and dummy connectors is not necessary.
Disconnection of jumper harness
2. Loosen the two bottom front screws fixing the MC unit to the controller (See figure
below.), then remove the MC unit from the controller by sliding forward then upward a
little. (The MC unit is hooked at the back.)
3. Mount a new MC unit to the controller in the reverse order of step 2 with the two screws
unscrewed in step 2 securely.
4. Reconnect the connectors disconnected in step 1.
MC unit
Two screws (at bottom)
(e.g.: E2x controller)
！
CAUTION
MC unit weighs approx. 7 kg. Be careful not to jam your
fingers when replacing the MC unit.
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Kawasaki Robot Troubleshooting Manual
4.4.2
4. Procedures for Replacement
1TQ/1TV BOARDS (MC CONTROL BOARD)
！ DANGER
Before starting replacement work, turn OFF the
controller power and wait at least three minutes.
1. Dismount the MC unit.
Refer to “4.4.1 MC Unit” for the procedure.
2. Unscrew the two screws fixing the MC unit front cover and remove the cover, the
1TQ/1TV boards can be seen. (1TQ is the front board and 1TV is the back board, and the
two boards are mounted as a pair.)
Screws
Front cover
Upper side
1TQ board
1TV board
Right side
4-16
E Series Controller
Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
3. Unscrew the four screws fixing the 1TV board (back board) to the MC unit.
4. Pull out the 1TQ/1TV boards and disconnect all connectors mounted on the back of the
1TV board.
Screws
Front
1TV board
1TQ board
Right side
5. Reconnect all connectors disconnected in step 4 to a new 1TQ/1TV boards, and fix the
boards to the MC unit with the four screws unscrewed in step 3. Be careful not to
damage the wiring at the time.
6. Remount the front cover removed in step 2 by fixing the two screws unscrewed in step 2.
7. Remount the MC unit to the controller. Refer to “4.4.1 MC Unit” for the procedure.
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Kawasaki Robot Troubleshooting Manual
4.5
4. Procedures for Replacement
FANS
Fans are mounted in the card rack, on top of the servo amplifier unit for six axes and
amplifier unit for single axis, and in the MC unit. This section describes the procedure for
replacement of these fans.
！
CAUTION
Fans may not be clean depending on the environment. In
that case, prevent dust falling from the fan onto the boards
of the controller by placing a sheet, etc. under the fan
during the replacement work.
4.5.1
FANS FOR CARD RACK
1. Turn OFF the controller power, and wait until the fan stops.
2. Disconnect the two connectors on the plastic fan unit (two fans built-in) on top of the card
rack. Then, pull the two handles to remove the fan unit.
3. Mount a new fan unit in the reverse order of step 2.
Connectors
Handles
4.5.2
FANS FOR SERVO AMP. UNIT FOR 6 AXES
The same parts are used here as the fan unit for card rack. The replacement procedure is
also the same. For the place where the fans are mounted, refer to the drawings shown in
4.5.4.
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Kawasaki Robot Troubleshooting Manual
4.5.3
4. Procedures for Replacement
FAN FOR AMP. UNIT FOR SINGLE AXIS
Different parts are used here from the fan unit for card rack (single fan built-in), but the
replacement procedure is the same as the fan unit for card rack. For the place where the fan
is mounted, refer to the drawings shown in 4.5.4.
Connector
Handle
4.5.4
FAN INSIDE MC UNIT
1. Turn OFF the controller power, and wait until the fan stops.
2. Disconnect the “XFAN” connector on upper right of the MC unit front. Unscrew the two
screws on top of the MC unit (See figure below.) and dismount the fan unit.
Screws
Fan unit
XFAN
connector
Fan unit
MC unit front
Top view
3. Unscrew the four screws fixing the fan (harness set) and remove the fan.
Screws
Bottom view
4-19
E Series Controller
Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
4. Mount a new fan (harness set) to the plate with the four screws securely.
correctly mount the fan in the same direction as the old fan.
Be sure to
5. Remount the fan unit with the two screws to top of the MC unit, and reconnect the
connector disconnected in step 2.
For warning of W1053, see the note below.
[ NOTE ]
In the E series controller, the rotation speed of the fan for the 1TQ board in the
MC unit is monitored. If the rotation speed decreases, a message such as
“(W1053) (FAN1-6) Rotational speed of fan is below the limit.” is displayed.
“FAN1-6” in the message stands for the number of fan and means “Fan
number 6” of “MC unit 1”.
Locations and numbers of fans are shown below.
1-1
1-1
1-2
1-2
1-3
1-3
1-4
1-4
1-5
1-5
1-6
1-6
E4x controller
E2x controller
4-20
E Series Controller
Kawasaki Robot Troubleshooting Manual
4.6
4. Procedures for Replacement
BATTERIES
This section describes the replacement procedure for the battery provided to backup time, etc.
4.6.1
COIN BATTERY ON 1TA BOARD
As backup power supply for RTC (Real Time Clock) and BIOS setting, the 1TA board is
equipped with a coin battery.
When on-board coin battery is removed, RTC and BIOS setting are initialized.
them by following the procedure below.
Restore
1. Before replacing the coin battery, confirm that the new battery is one specified by KHI for
3 V supply.
2. Turn OFF the controller power.
3. Pull out the 1TA board and remove the coin battery from its holder.
pulling out the board, refer to 4.2.1 1TA board.
For procedure for
4. After setting a new battery to the holder, put back the 1TA board to the original place.
5. When a sticker is put on the old battery, the initialization value in the BIOS setting is
modified. For the initialization value and modification procedure, contact Kawasaki.
6. Turn ON the controller power.
7. Set time referring to time setting in Operation Manual, etc.
Coin battery
1TA board
[ NOTE ]
・ In the 1TA board, user data is stored in the CF card. Thus,
user program is not deleted when the coin battery is replaced.
・ The coin battery has a life of approx. 10 years.
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Kawasaki Robot Troubleshooting Manual
4.6.2
4. Procedures for Replacement
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 +3.6 V or more voltage.
3. Turn OFF the controller power.
4. For the 1HG board, pull out the connector box located on the base of the robot main body.
For the 1FG board, dismount the plate that the battery is mounted.
5. Disconnect the battery connector (CN10 for 1FG, CN4 for 1HG), cut two tying bands
fixing the battery, and remove the battery.
6. Fix a new battery with two tying bands, and reconnect the connector disconnected in step
4.
7. For the 1HG board, set the connector box to the original place.
plate that the battery is mounted to the original place.
8. Mount the cover to the robot arm.
value has not changed.
！
For the 1FG board, set the
Turn ON the controller power and check if the encoder
CAUTION
1. Battery life is about two years (assuming controller power is continuously
OFF), but the lifetime differs depending on ambient temperature, etc.
2. While replacing a battery, the built-in super capacitor maintains encoder
values for approximately 30 minutes on a full charge. So, replace a battery
within 30 minutes. (Note that if the super capacitor is not fully charged, the
data retention time is less than 30 minutes.)
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Kawasaki Robot Troubleshooting Manual
4.7
4. Procedures for Replacement
FUSES
This section describes the procedure for replacement of the fuses.
4.7.1
FUSES ON 1TR BOARD
One type of fuse (Fuse1) is mounted on the 1TR board.
1. Turn OFF the controller power.
2. Push the fuse on front of the 1TR board and turn it 90 degrees to the left.
to remove it from the board.
3. Push a new fuse, and turn it 90 degrees to the right to mount.
Fuse 1
1KP
ボ
Outline view of 1TR board
4-23
Then pull it out
E Series Controller
Kawasaki Robot Troubleshooting Manual
4. Procedures for Replacement
MEMO
4-24
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
5.0
SCHEMATIC DIAGRAMS OF SEPARATE AND MACHINE HARNESSES
This chapter compiles a listing of the electrical schematic diagrams for the separate and
machine harnesses and the wire distribution lists for the E Series Controller. Please note that
this information is provided for reference purposes only and should not be applied as the basis
of maintenance or repair operations.
5.1
5.1.1
5.1.2
5.1.3
5.2
5.2.1
5.2.2
5.2.3
5.2.4
Separate Harness････････････････････････････････････････････････････････････ 5-2
E20/E40 Separate Harness Wire Distribution List ･･････････････････････････････ 5-2
E22/E42 Separate Harness Wire Distribution List ･･････････････････････････････ 5-4
E24/E44 Separate Harness Wire Distribution List ･･････････････････････････････ 5-6
Machine Harness ･･･････････････････････････････････････････････････････････ 5-8
R Series････････････････････････････････････････････････････････････････････ 5-8
ZX, ZT Series ･････････････････････････････････････････････････････････････ 5-11
MX Series ････････････････････････････････････････････････････････････････ 5-15
MD Series ････････････････････････････････････････････････････････････････ 5-19
5-1
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
5.1
5.1.1
SEPARATE HARNESS
E20/E40 SEPARATE HARNESS WIRE DISTRIBUTION LIST
1. Signal Harness
X3
Signal name
JT1-ENCP
JT1-ENCN
JT2-ENCP
JT2-ENCN
JT3-ENCP
JT3-ENCN
JT4-ENCP
JT4-ENCN
JT5-ENCP
JT5-ENCN
JT6-ENCP
JT6-ENCN
JT7-ENCP
JT7-ENCN
EPVP
EPVN
LS1P
LS1N
LS2P
LS2N
+12V
GND
GND
BAT ALP
BAT ALN
+12V
GND
GND
+12V
GND
GND
SIG-1
SIG-2
SIG-3
SIG-4
I/O 24V
I/O 24G
I/O 24V
I/O 24G
SPARE
SPARE
SHIELD
No.
1
8
2
9
3
10
4
11
5
12
6
13
7
14
22
23
27
34
28
35
36
29
30
20
21
31
37
38
32
24
25
15
16
17
18
39
40
33
26
41
42
L
Destination
X3A-1
X3A-8
X3A-2
X3A-9
X3A-3
X3A-10
X3A-4
X3A-11
X3A-5
X3A-12
X3A-6
X3A-13
X3A-7
X3A-14
X3A-22
X3A-23
X3A-27
X3A-34
X3A-28
X3A-35
X3A-36
X3A-29
X3A-30
X3A-20
X3A-21
X3A-31
X3A-37
X3A-38
X3A-32
X3A-24
X3A-25
X3A-15
X3A-16
X3A-17
X3A-18
X3A-39
X3A-40
X3A-33
X3A-26
X3A-41
X3A-42
X3AL
5-2
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
2. Motor Harness
X4
Signal Name
JT1-MOTOR U
JT1-MOTOR V
JT1-MOTOR W
JT2-MOTOR U
JT2-MOTOR V
JT2-MOTOR W
JT3-MOTOR U
JT3-MOTOR V
JT3-MOTOR W
JT4-MOTOR U
JT4-MOTOR V
JT4-MOTOR W
JT5-MOTOR U
JT5-MOTOR V
JT5-MOTOR W
JT6-MOTOR U
JT6-MOTOR V
JT6-MOTOR W
JT7-MOTOR U
JT7-MOTOR V
JT7-MOTOR W
TH P
TH N
SHIELD
EARTH
No.
1
13
25
2
14
26
3
15
27
4
16
28
5
17
29
6
18
30
7
19
31
69
70
L
59
Signal Name
EARTH
JT1-BRAKE P
JT1-BRAKE N
JT2-BRAKE P
JT2-BRAKE N
JT3-BRAKE P
JT3-BRAKE N
JT4-BRAKE P
JT4-BRAKE N
JT5-BRAKE P
JT5-BRAKE N
JT6-BRAKE P
JT6-BRAKE N
JT7-BRAKE P
JT7-BRAKE N
SIGO-1
SIGO-2
SIGO-3
SIGO-4
SIGO-5
SIGO-6
SIGO-7
SIGO-8
SPARE
SPARE
SPARE
SPARE
Destination
X4A-1
X4A-13
X4A-25
X4A-2
X4A-14
X4A-26
X4A-3
X4A-15
X4A-27
X4A-4
X4A-16
X4A-28
X4A-5
X3A-17
X4A-29
X4A-6
X4A-18
X4A-30
X4A-7
X4A-19
X4A-31
X4A-69
X4A-70
X4AL
X4A-59
No.
U
37
49
38
50
39
51
40
52
41
53
42
54
43
55
61
62
63
64
65
66
67
68
12
36
71
72
Destination
X4AU
X4A-37
X4A-49
X4A-38
X4A-50
X4A-39
X4A-51
X4A-40
X4A-52
X4A-41
X4A-53
X4A-42
X4A-54
X4A-43
X4A-55
X4A-61
X4A-62
X4A-63
X4A-64
X4A-65
X4A-66
X4A-67
X4A-68
X4A-12
X4A-36
X4A-71
X4A-72
Connection between controller and robot
Controller side
Robot side
X4A
Motor harness (X4)
Signal harness (X3)
Rear view of E20 controller
5-3
X3A
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
5.1.2
E22/E42 SEPARATE HARNESS WIRE DISTRIBUTION LIST
1. Signal Harness
2. Base Axis Motor Harness
X3 (Z Series)
X4 (Z Series)
Signal Name
JT1-ENCP
JT1-ENCN
JT3-ENCP
JT3-ENCN
JT4-ENCP
JT4-ENCN
JT6-ENCP
JT6-ENCN
JT2-ENCP
JT2-ENCN
JT7-ENCP
JT7-ENCN
JT5-ENCP
JT5-ENCN
EPVP
EPVN
LS1P
LS1N
LS2P
LS2N
+12V
GND
GND
BAT-ALP
BAT-ALN
+12V
GND
GND
+12V
GND
GND
SIG-1
SIG-2
SIG-3
SIG-4
I/O 24V
I/O 24G
I/O 24V
I/O 24G
SHIELD
No.
1
8
3
10
4
11
6
13
2
9
7
14
5
12
22
23
27
34
28
35
36
29
30
20
21
31
37
38
32
24
25
15
16
17
18
39
40
33
26
L
Signal Name
JT1-MOTOR U
JT1-MOTOR V
JT1-MOTOR W
JT2-MOTOR U
JT2-MOTOR V
JT2-MOTOR W
JT3-MOTOR U
JT3-MOTOR V
JT3-MOTOR W
−
−
−
TH P
TH N
EARTH
SHIELD
Destination
X3A-1
X3A-8
X3A-3
X3A-10
X3A-4
X3A-11
X3A-6
X3A-13
X3A-2
X3A-9
X3A-7
X3A-14
X3A-5
X3A-12
X3A-22
X3A-23
X3A-27
X3A-34
X3A-28
X3A-35
X3A-36
X3A-29
X3A-30
X3A-20
X3A-21
X3A-31
X3A-37
X3A-38
X3A-32
X3A-24
X3A-25
X3A-15
X3A-16
X3A-17
X3A-18
X3A-39
X3A-40
X3A-33
X3A-26
X3A- L
5-4
No.
1
2
3
4
5
6
7
8
9
10
11
12
a
b
U
L
Destination
X4A-1
X4A-2
X4A-3
X4A-4
X4A-5
X4A-6
X4A-7
X4A-8
X4A-9
X4A-a
X4A-b
X4A- U
X4A- L
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
X5 (Z Controller)
Signal Name
JT4-MOTOR U
JT4-MOTOR V
JT4-MOTOR W
JT5-MOTOR U
JT5-MOTOR V
JT5-MOTOR W
JT6-MOTOR U
JT6-MOTOR V
JT6-MOTOR W
JT7-MOTOR U
JT7-MOTOR V
JT7-MOTOR W
SHIELD
JT1-BRAKE P
JT1-BRAKE N
JT2-BRAKE P
JT2-BRAKE N
JT3-BRKAE P
JT3-BRAKE N
EARTH
No.
1
8
15
22
29
36
2
9
16
23
30
37
L
3
4
10
11
17
18
38
U
Destination
X5A-1
X5A-8
X5A-15
X5A-22
X5A-29
X5A-36
X5A-2
X5A-9
X5A-16
X5A-23
X5A-30
X5A-37
X5AL
X5A-3
X5A-4
X5A-10
X5A-11
X5A-17
X5A-18
X5A-38
X5AU
Signal Name
JT4-BRAKE P
JT4-BRAKE N
JT5-BRAKE P
JT5-BRAKE N
JT6-BRAKE P
JT6-BRAKE N
JT7-BRAKE P
JT7-BRAKE N
SIGO-1
SIGO-2
SIGO-3
SIGO-4
SIGO-5
SIGO-6
SIGO-7
SIGO-8
−
−
−
−
−
−
No.
24
25
31
32
5
6
12
13
19
20
26
27
33
34
40
41
7
14
21
28
35
42
Destination
X5A-24
X5A-25
X5A-31
X5A-32
X5A-5
X5A-6
X5A-12
X5A-13
X5A-19
X5A-20
X5A-26
X5A-27
X5A-33
X5A-34
X5A-40
X5A-41
Connection between controller and robot
Controller side
Robot side
X4A
Base axis motor harness
Wrist axis motor harness
Signal harness (X3)
E22 コントローラ 背
Rear
面view of E22 controller
5-5
X5A
X3A
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
5.1.3
E24/E44 SEPARATE HARNESS WIRE DISTRIBUTION LIST
1. Signal Harness
2-1. Base Axis Motor Harness (JT1-JT3)
X3
X4-1
Signal Name
JT1-ENCP
JT1-ENCN
JT2-ENCP
JT2-ENCN
JT3-ENCP
JT3-ENCN
JT4-ENCP
JT4-ENCN
JT5-ENCP
JT5-ENCN
JT6-ENCP
JT6-ENCN
JT7-ENCP
JT7-ENCN
EPVP
EPVN
LS1P
LS1N
LS2P
LS2N
+12V
GND
GND
BAT-ALP
BAT-ALN
+12V
GND
GND
+12V
GND
GND
SIG-1
SIG-2
SIG-3
SIG-4
I/O 24V
I/O 24G
I/O 24V
I/O 24G
SHEILD
No.
1
8
2
9
3
10
4
11
5
12
6
13
7
14
22
23
27
34
28
35
36
29
30
20
21
31
37
38
32
24
25
15
16
17
18
39
40
33
26
L
Destination
X3A-1
X3A-8
X3A-2
X3A-9
X3A-3
X3A-10
X3A-4
X3A-11
X3A-5
X3A-12
X3A-6
X3A-13
X3A-7
X3A-14
X3A-22
X3A-23
X3A-27
X3A-34
X3A-28
X3A-35
X3A-36
X3A-29
X3A-30
X3A-20
X3A-21
X3A-31
X3A-37
X3A-38
X3A-32
X3A-24
X3A-25
X3A-15
X3A-16
X3A-17
X3A-18
X3A-39
X3A-40
X3A-33
X3A-26
L
Signal Name
JT1-MOTOR U
JT1-MOTOR V
JT1-MOTOR W
JT2-MOTOR U
JT2-MOTOR V
JT2-MOTOR W
JT3-MOTOR U
JT3-MOTOR V
JT3-MOTOR W
TH P
TH N
EARTH
SHEILD
No.
1
2
3
4
5
6
7
8
9
a
b
U
L
Destination
X4A-1-1
X4A-1-2
X4A-1-3
X4A-1-4
X4A-1-5
X4A-1-6
X4A-1-7
X4A-1-8
X4A-1-9
X4A-1-a
X4A-1-b
X4A-1- U
X4A-1- L
2-2. Wrist Axis Motor Harness (JT4-JT6)
X4-2
Signal Name
JT4-MOTOR U
JT4-MOTOR V
JT4-MOTOR W
JT5-MOTOR U
JT5-MOTOR V
JT5-MOTOR W
JT6-MOTOR U
JT6-MOTOR V
JT6-MOTOR W
TH P
TH N
EARTH
SHEILD
5-6
No.
1
2
3
4
5
6
7
8
9
a
b
U
L
Destination
X4A-2-1
X4A-2-2
X4A-2-3
X4A-2-4
X4A-2-5
X4A-2-6
X4A-2-7
X4A-2-8
X4A-2-9
X4A-2-a
X4A-2-b
X4A-2- U
X4A-2- L
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
3. Motor Harness
X5
Signal Name
JT4-MOTOR U
JT4-MOTOR V
JT4-MOTOR W
JT5-MOTOR U
JT5-MOTOR V
JT5-MOTOR W
JT6-MOTOR U
JT6-MOTOR V
JT6-MOTOR W
JT7-MOTOR U
JT7-MOTOR V
JT7-MOTOR W
SHIELD
JT1-BRAKE P
JT1-BRAKE N
JT2-BRAKE P
JT2-BRAKE N
JT3-BRAKE P
JT3-BRAKE N
EARTH
No.
1
8
15
22
29
36
2
9
16
23
30
37
L
3
4
10
11
17
18
38
U
Signal Name
JT4-BRAKE P
JT4-BRAKE N
JT5-BRAKE P
JT5-BRAKE N
JT6-BRAKE P
JT6-BRAKE N
JT7-BRAKE P
JT7-BRAKE N
SIGO-1
SIGO-2
SIGO-3
SIGO-4
SIGO-5
SIGO-6
SIGO-7
SIGO-8
−
−
−
−
−
−
Destination
X5A-1
X5A-8
X5A-15
X5A-22
X5A-29
X5A-36
X5A-2
X5A-9
X5A-16
X5A-23
X5A-30
X5A-37
X5AL
X5A-3
X5A-4
X5A-10
X5A-11
X5A-17
X5A-18
X5A-38
X5AU
No.
24
25
31
32
5
6
12
13
19
20
26
27
33
34
40
41
7
14
21
28
35
42
Destination
X5A-24
X5A-25
X5A-31
X5A-32
X5A-5
X5A-6
X5A-12
X5A-13
X5A-19
X5A-20
X5A-26
X5A-27
X5A-33
X5A-34
X5A-40
X5A-41
Connection between controller and robot
Robot side
Controller side
X5
X4A-2
X4A-1
Motor harness (X4-2)
Base axis motor harness (X4-1)
Wrist axis motor harness (X5)
Signal harness (X3)
Rear view of E24 controller
5-7
X3
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
5.2 MACHINE HARNESS
5.2.1 R SERIES
Motor
Motor
ID board
Motor
Motor
Motor
Motor
RS20N Machine Harness Schematic Diagram
OUTSIDE ROBOT
5-8
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
RS20N Machine Harness Connection Diagram (1/2)
5-9
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
RS20N Machine Harness Connection Diagram (2/2)
5-10
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
Base section
Lower arm section
Link section
Forearm section
5.2.2 ZX, ZT SERIES
ZX, ZT Series Machine Harness Schematic Diagram
5-11
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
5-12
BRAKE
BRAKE
BRAKE
BRAKE
BRAKE
BRAKE
BRAKE
ZX Series Machine Harness Connection Diagram (1/3)
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
ZX Series Machine Harness Connection Diagram (2/3)
5-13
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
ZX Series Machine Harness Connection Diagram (3/3)
5-14
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
Base section
Lower arm section
Link section
Forearm section
Option BOX
5.2.3 MX SERIES
MX Series Machine Harness Schematic Diagram
5-15
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
MX Series Machine Harness Connection Diagram (1/3)
5-16
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
MX Series Machine Harness Connection Diagram (2/3)
5-17
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
MX Series Machine Harness Connection Diagram (3/3)
5-18
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
Base section
Lower arm section
Link section
Forearm section
5.2.4 MD SERIES
MD Series Machine Harness Schematic Diagram
5-19
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
MD Series Machine Harness Connection Diagram (1/3)
5-20
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
MD Series Machine Harness Connection Diagram (2/3)
5-21
E Series Controller
5. Schematic Diagrams of Separate and Machine Harnesses
Kawasaki Robot Troubleshooting Manual
MD Series Machine Harness Connection Diagram (3/3)
5-22
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
APPENDIX ERROR MESSAGE LIST
Code
Error Message
P0100
P0101
P0102
P0103
P0104
P0105
P0106
P0107
P0108
P0109
Illegal input data.
Too many arguments.
Input data is too big.
Illegal PC number.
Illegal Robot number.
Illegal program.
Illegal priority.
Invalid coordinate value.
Syntax error.
Invalid statement.
P0110
P0111
P0112
P0113
P0114
P0115
P0116
P0117
P0118
P0119
P0120
P0121
P0122
P0123
P0124
P0125
Specify full spelling of command.
Cannot use this command/instruction in current mode.
Cannot execute with DO command.
Not a program instruction.
Illegal expression.
Illegal function.
Illegal argument of function.
Invalid variable (or program) name.
Illegal variable type.
Incorrect array suffix.
Incongruent num. of parenthesis.
Expected to be a binary operator.
Illegal constant.
Illegal qualifier.
Invalid label.
Missing expected character.
P0126
P0127
P0128
P0129
P0130
P0131
P0132
P0133
Illegal switch name.
Specified switch name needs full spelling.
Illegal format specifier.
Duplicate statement label.
Cannot define as array.
No. of dimensions in array exceeds 3.
Array variable already exists.
Non array variable exists.
A-1
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P0134
P0135
P0136
P0137
P0138
P0139
P0140
P0141
P0142
P0143
P0144
P0145
P0146
P0147
P0148
P0149
P0150
P0151
P0152
P0153
P0154
P0155
P0156
P0157
P0158
P0159
P0160
P0161
P0162
P0163
P0164
P0165
P0166
Error Message
Array variable expected.
Local variable expected.
Unexpected suffix.
Mismatch of arguments at subroutine call.
Mismatch of argument type at subroutine call.
Illegal control structure.
Step:XX Wrong END statement.
Step:XX Extra END statement.
Step:XX Cannot terminate DO with END.
Step:XX No VALUE statement after CASE.
Step:XX Preceding IF missing.
Step:XX Preceding CASE missing.
Step:XX Preceding DO missing.
Step:XX Cannot find END of XX.
Step:XX Too many control structures.
Variable (or program) already exists.
Variable of different type already exists.
Internal buffer over due to complicated expression.
Undefined variable (or program).
Illegal clock value.
Missing '='.
Missing ')'.
Missing ']'.
Missing "TO".
Missing "BY".
Missing ':'.
Specify "ON" or "OFF".
Robot Num. must be specified.
Cannot modify position data in this instruction.
Name of program, variable, file, etc. misspecified.
Illegal Robot network ID.
Step:XX No SVALUE statement after SCASE.
Step:XX Preceding SCASE missing.
P1000
P1001
P1002
Cannot execute program because motor power is OFF.
Cannot execute program in TEACH mode.
Cannot execute program because teach lock is ON.
A-2
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P1003
P1004
P1005
P1006
P1007
P1008
P1009
P1010
P1011
P1012
P1013
P1014
P1015
P1016
P1017
P1018
P1019
P1020
P1021
P1022
P1023
P1024
P1025
P1026
P1027
P1028
P1029
P1030
P1031
P1032
P1033
P1034
P1035
Error Message
Cannot execute program because of EXT. HOLD input.
Cannot execute program being reset.
Cannot execute program because of EXT. START ENABLE.
Cannot execute program because of EXT. START DISABLE.
Start signal was not input at a RPS_END step.
Cannot execute program, HOLD sw. engaged.
Program is already running.
Robot control program is already running.
Cannot continue this program. Use EXECUTE.
Robot is moving now.
Cannot execute because in error now. Reset error.
Cannot execute because program already in use.
Cannot delete, in use by another command.
Cannot delete, used in program.
Cannot delete a program in Editor.
KILL or PCKILL to delete program.
PC program is running.
Cannot operate, teach pendant in operation.
Cannot execute with DO command.
Cannot execute with MC instruction.
Cannot execute in Robot program.
Statement cannot be executed.
Cannot be executed, function not set.
Cannot KILL program that is running.
Cannot edit program, teach lock is ON.
Cannot paste.
Program name not specified.
Program interlocked by other procedure.
No free memory.
No program step.
Program name already exists.
This program is not editable.
Record inhibited. Set [Record Accept] and operate again.
P1036
P1037
P1038
Program change inhibited. Set [Accept] and operate again.
Program name cannot be called "calib_load_".
Program does not exist.
A-3
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P1039
P1040
P1041
P1042
P1043
P1044
P1045
P1046
P1047
P1048
P1049
P1050
P1051
P1052
P1053
P1054
P1055
P1056
P2000
P2001
P2002
P2003
P2004
P2005
P2006
P2007
P2008
P2009
P2010
P2011
P2012
P2013
P2014
Error Message
Teach pendant is not connected.
Cannot execute this command in I/F panel.
Auto monitor command failure.
NUM program is running.
Cannot execute in REPEAT mode.
Cannot execute on because motor power is ON.
Set TEACH mode and teach lock ON.
Turn on trigger switch.
The disconnected robot cannot select the program/step.
Cannot operate during execution of brake check.
Program is locked.
Exist protected program.
Cannot unlock protection while program running.
Because the memory was full, could not copy the program.
Because the memory was full, the copy of program was suspended.
Turn off trigger switch.
Teach the axis lock instruction at the step of clamp ON.
Teach the axis unlocking instruction at the step of clamp ON.
Turn OFF motor power.
Turn HOLD/RUN sw. to HOLD.
There is no external axis.
Illegal positioner type.
Cannot change, user data already exists.
Graphic area error.
Option is OFF.
Cannot execute because executed by other device.
Device is not ready.
Illegal file name.
Disk is not ready.
Invalid disk format.
Disk is write-protected.
Disk full.
Too many files.
P2015
P2016
P2017
Cannot write on read-only file.
Cannot open the file.
Cannot close the file.
A-4
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P2018
P2019
P2020
P2021
P2022
P2023
P2024
P2025
P2026
P2027
P2028
P2029
P2030
P2031
P2032
P2033
P2034
P2035
P2036
P2037
P2038
P2039
P2040
P2041
P2042
P2043
P2044
P2045
P2046
P2047
P2048
P2049
P2050
Error Message
Storage data logging now.
ADC function already in use.
Illegal device number.
Cannot execute on this terminal.
Cannot use DOUBLE OX.
In cooperative mode.
Invalid coordinate value X.
Invalid coordinate value Y.
Invalid coordinate value Z.
Cannot use signal, already used in I/F panel.
Arm ID board is busy.
Axis setting data is incorrect.
Unknown Aux. function number.
Deleted step was destination step of Jump, Call instruction.
Incorrect number input as WHERE parameter.
Logging is running.
Undefined memory.
Non data.
Memory verify error.
Real time path modulation is already running.
Matrix calculation error.
Cannot start cycle from FN instruction.
Card is not ready.
Wrong card loaded.
Card is write-protected.
Card battery is low voltage.
Card is not formatted.
Cannot format this card.
Card initialization error.
File is already open.
File does not exist in card.
Attempted to open too many files.
Unexpected error during card access.
P2051
P2052
P2053
Illegal sequence numbers for file I/O data.
[LSEQ]Program includes unavailable instruction.
[LSEQ]Too many steps exist.
A-5
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P2054
P2055
P2056
P2057
P2058
P2059
P2060
P2061
P2062
P2063
P2064
P2065
P2066
P2067
P2068
P2069
P2070
P2071
P2072
P2073
P2074
P2075
P2076
P2077
P2078
P2079
P2080
P2083
P2084
P2085
P2086
P2087
P2088
Error Message
[LSEQ]Invalid type of signal variable.
[LSEQ]Program is already running.
[LSEQ]No.of signal is outside specifiable range.
[SerialFlash]Cannot open file.
[SerialFlash]Data read error.
[SerialFlash]Data write error.
[SerialFlash]File or directory doesn't exist.
File does not exist in floppy.
[FDD/PC_CARD]Failure in writing data per verify function.
[FDD/PC_CARD]Faulty response from verify function.
[FDD]No space available.
[Multi Disks]Invalid disk was loaded.
Boot flash state is write-disenable.
[Serial Flash]File directory error.
Cannot execute program being edited now.
[FDD/PC_CARD]Device already in use.
No more data can be registered.
C/S switch set to disable.
[LSEQ]Maximum cycles of execution.
[LSEQ]Other program is waiting execution.
Floppy disk is broken.
Channel number for JtXX is incorrect.
SAVE/LOAD in progress.
[Serial Flash]Access error occurred.
[Serial Flash]Upload or Download was aborted.
Card full.
Can not execute because of the channel assigned joint No.
User log is not created.
The number of registration of a user log was changed.
Cannot register user log, no free memory.
User log data is not registered.
The kind of user log data and specified data is different.
Cannot load the improper compensation parameter.
P2090
P2091
P2092
No servo data of the servo spec.
[Serial Flash]The file or directory already exists.
[Serial Flash]The directory is not yet empty.
A-6
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P2093
P2094
P2095
P2096
P2097
P2098
P2099
P2100
P2101
P2102
P2103
P2104
P2105
P2106
P2107
P2108
P2109
P2110
P2111
P2112
P2113
P4500
P4501
P4502
P4503
P4504
P4505
P4506
Error Message
[Serial Flash]There is no space to write.
[Serial Flash]Cannot access the file for read only.
No response from option CPU board.
Cannot execute cycle start after palletizing motion aborted.
Cannot change steps during palletizing motion.
The axis is not for endless rotation.
Cannot change palletizing state into ON.
Macro error.
Nesting is too deep in include file.
File or folder is missing.
USB memory is not inserted.
Failed to download softwares.
Available USB memory is low.
Available compact flash memory is low.
System is now downloading the software.
There is no software in the USB memory.
Cannot execute program because of simultaneously operation sig. inputting.
[USB/CF]File write error.
Please return spin-axis to the original position.
File name is too long.
Cannot start cycle from KI instruction.
FIELD-BUS)Interface not enabled.
DEVNET)Node XX not in the scanlist.
DEVNET)Already in that mode.
Duplicate signal number.
FIELD-BUS)signals limit over.(max. XX)
CC-LINK)Version mismatch.
EN/IP-M)Already in specified mode.
P4507
P4508
P4509
P4510
P5000
P5001
P5002
P5003
FIELD-BUS)Cannot execute with old ANYBUS card firmware.
FIELD-BUS)Cannot communicate with interface card.
FIELD-BUS)Wrong interface card type error.
FIELD-BUS)Initialization of the card is not complete.
Waiting weld completion.
Waiting retract or extend pos. input signal.
Spot sequence is running.
External-axis type and Gun type data mismatch.
A-7
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P6000
P6001
P6002
P6003
P6004
P6005
P6006
P6007
P6008
P6009
P6010
P6011
P6012
P6500
P6501
P6502
P6503
P6504
P6505
P6506
P7000
P7001
P7002
P7003
P7500
P7501
P7502
P7503
P7504
P7505
P7506
P7507
P8400
Error Message
Shifted location of STEPXX is out of range.
STEPXX in source program is out of motion range.
Specified painting data bank does not exist.
Cannot execute program because of suspend playback.
Cannot execute because of the Air Purge sequence.
Cannot execute because robot is disconnected.
Cannot specify circular move to end point of spraying path.
Number of taught points for spraying path exceeds the limit.
Number of instructions between points exceeds the limit.
Shortage in number of taught points for spraying path.
Selected program other than pgxxx.
Cannot move, change to joint interpolation or add points.
Cannot edit program, TEACH LOCK is OFF.
Cannot generate working line direction.
Illegal tool posture.
No weld database.
Cannot change weld condition.
Step:XX Preceding L.START missing.
The axis type is not set as the servo torch.
Shift function can not be used in CIR interp.
Cannot program reset, because not at home position 1.
In force meas. mode, only NOP Interp. avail.
Cannot change stroke because clamp on now.
Servo parameter file is not found.
Turn motor power on.
Because of repeat mode,wait to teach mode.
Over the number which can be registered in interruption.
Cannot execute program in error masking.
ONC/ONCI channel has already received.
Cannot execute in saving.
Cannot accept a record because robot is moving.
Amount of the data change is too large in repeat operation.
Cannot execute program because of CLAMP MODE sig. inputting.
P8800
P8801
P8802
The controller number is duplicated.
The IL robot number is duplicated.
The IL server is processing.
A-8
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
P8803
P8804
P8805
P8806
P8807
P8808
P8809
P8810
P8811
P8812
P8813
P9000
Error Message
The connection with the IL server is disabled.
IL server IP address is not yet set.
Set the mode to Teach.
Turn off servo.
ILL)Communication time out error.
ILL)Time out error for PC server processing.
ILL)PC server processing demand completion waiting is time out error.
ILL)Error in auto interlock setting system.
ILL)Could not release operation lock for slave controller.
ILL)Could not communicate with the PC server.
The IL robot number is unregistered.
Unacceptable control-direction.
P9001
P9002
P9003
P9004
P9005
W1000
W1001
W1002
W1003
W1004
W1005
W1006
W1007
W1008
W1009
W1010
Unacceptable control-distance.
Same data are specified for some reference points.
Reference points1,2,3 are on a straight line.
Reference point 4 is out of allowed range.
Cannot manipulate because teach lock is ON.
Cannot move along straight line JtXX in this configuration.
Over maximum joint speed in check. Set low speed.
Operation log information was cleared.
Calibration failed. Retry after changing posture.
JtXX out of motion range. Check operational area.
Illegal center of gravity, default parameter is set.
Incorrect load moment. Default parameter is set.
Application setting changed. Turn OFF & ON the control power.
Parameter changed. Turn OFF & ON the control power.
Position envelope error of JtXX at last E-stop.
RAM battery low voltage.
W1011
W1012
W1013
W1014
W1015
W1016
W1017
W1018
PLC alarm. (XX)
Servo parameter changed. Turn OFF & ON the control power.
Encoder battery low voltage. [Servo(XX)]
Number of axes changed. Reinitialize.
Possibility of failure.
Torque of motor is over limit. JtXX
Encoder battery low voltage.[External axis(XX)]
Network parameter is changed. Turn OFF & ON the control power.
A-9
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
W1019
W1020
W1021
W1022
W1023
W1024
W1025
W1026
W1027
W1028
W1029
W1030
Error Message
The registered value is beyond rated load.
Error sector was found.
The optimal posture can't be found at present location.
Not execute ZRPAADSET command.
Teach Plug Position wrong or P-N low voltage.[XX]
Deviation from last stop position exceeds the limit set.
(SSCNET)Excessive regenerative warning of JtXX.(CodeXX)
(SSCNET)Motor overload warning of JtXX.(CodeXX)
While lifter is locked, it cannot move.
The center of gravity for payload is over limit. Reduction gears could be broken.
The center of gravity for payload is over limit. Use the Jt5 at zero degree only.
Braking torque of JtXX has decreased.
W1031
W1032
W1033
W1034
W1035
W1036
W1037
W1038
W1039
W1040
W1041
W1042
W1043
W1044
W1045
W1046
W1047
W1048
W1049
W1050
W1051
W1052
W1053
W1054
W1055
Cannot move along straight line unless JtXX value is 0 degree.
Cannot move straight - the flange faces direction of upper sphere.
Cannot change orientation.
Encoder power voltage is low. JtXX
Encoder battery voltage is low. Check zeroing . JtXX
Step data is different.
The axis is not for endless rotation.
Encoder rotation data is abnormal.(JtXX)
Encoder response error.(JtXX)
Encoder communication error.(JtXX)
Speed error JtXX.
Encoder rotation speed exceeded limit (JtXX)
Encoder temperature exceeded limit (JtXX)
Velocity envelope error in endless rotation axis.(JtXX)
Abn. curr feedback JtXX. (Amp fail, pwr harness disconnect)
Encoder ABS-track error.(JtXX)
Encoder INC-pulse error.(JtXX)
No. of encoder errors exceeded limit JtXX.
RSC)TCP communication error occurred.(Code:XX)
RSC)Command value output communication error occurred. (Code:XX)
RSC)USB communication initialize error occurred.(Code:XX)
RSC)RC parameter generation error occurred.(Code:XX)
(FANXX-XX)Rotational speed of fan is below the limit. (ServoBoardXX)
AVR reaches the expected lifetime soon.
Vision cycle timer over.
A-10
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
W1056
W1057
W1058
W1059
W1060
W1061
W1062
W1063
Appendix. Error Message List
W1064
W2901
W2902
W2903
Error Message
[Main CPU board]CPU temperature exceeded the limit. (XX 1/1000 deg C)
Cannot move along straight line tool in this configuration.
Link3 interferes in ground.
Link5 interferes in base.
Link6 interferes in base.
TP changed. Confirm current pose, and operate the robot.
The TP backlight lighting time exceeded the limit.
The number of ON/OFF operations of MC relay exceeded the
limit.(SrvB'dXX)(MCXX)
Exceeded the limit.(Parts:XX)
SLOGIC ERROR MESSAGE #1
SLOGIC ERROR MESSAGE #2
SLOGIC ERROR MESSAGE #3
W2904
W2905
W2906
W2907
W2908
W2909
W2910
W2911
W2912
W2913
W2914
W2915
W2916
W2917
W2918
W2919
W2920
W2921
W2922
W2923
W2924
W2925
W2926
W2927
SLOGIC ERROR MESSAGE #4
SLOGIC ERROR MESSAGE #5
SLOGIC ERROR MESSAGE #6
SLOGIC ERROR MESSAGE #7
SLOGIC ERROR MESSAGE #8
SLOGIC ERROR MESSAGE #9
SLOGIC ERROR MESSAGE #10
SLOGIC ERROR MESSAGE #11
SLOGIC ERROR MESSAGE #12
SLOGIC ERROR MESSAGE #13
SLOGIC ERROR MESSAGE #14
SLOGIC ERROR MESSAGE #15
SLOGIC ERROR MESSAGE #16
SLOGIC ERROR MESSAGE #17
SLOGIC ERROR MESSAGE #18
SLOGIC ERROR MESSAGE #19
SLOGIC ERROR MESSAGE #20
SLOGIC ERROR MESSAGE #21
SLOGIC ERROR MESSAGE #22
SLOGIC ERROR MESSAGE #23
SLOGIC ERROR MESSAGE #24
SLOGIC ERROR MESSAGE #25
SLOGIC ERROR MESSAGE #26
SLOGIC ERROR MESSAGE #27
A-11
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
W2928
W2929
W2930
W2931
W2932
W2933
W2934
W2935
W2936
W2937
W2938
W2939
W2940
W2941
W2942
W2943
W2944
W2945
W2946
W2947
W2948
W2949
W2950
W2951
W2952
W2953
W2954
W2955
W2956
W2957
W2958
W2959
W2960
Error Message
SLOGIC ERROR MESSAGE #28
SLOGIC ERROR MESSAGE #29
SLOGIC ERROR MESSAGE #30
SLOGIC ERROR MESSAGE #31
SLOGIC ERROR MESSAGE #32
SLOGIC ERROR MESSAGE #33
SLOGIC ERROR MESSAGE #34
SLOGIC ERROR MESSAGE #35
SLOGIC ERROR MESSAGE #36
SLOGIC ERROR MESSAGE #37
SLOGIC ERROR MESSAGE #38
SLOGIC ERROR MESSAGE #39
SLOGIC ERROR MESSAGE #40
SLOGIC ERROR MESSAGE #41
SLOGIC ERROR MESSAGE #42
SLOGIC ERROR MESSAGE #43
SLOGIC ERROR MESSAGE #44
SLOGIC ERROR MESSAGE #45
SLOGIC ERROR MESSAGE #46
SLOGIC ERROR MESSAGE #47
SLOGIC ERROR MESSAGE #48
SLOGIC ERROR MESSAGE #49
SLOGIC ERROR MESSAGE #50
SLOGIC ERROR MESSAGE #51
SLOGIC ERROR MESSAGE #52
SLOGIC ERROR MESSAGE #53
SLOGIC ERROR MESSAGE #54
SLOGIC ERROR MESSAGE #55
SLOGIC ERROR MESSAGE #56
SLOGIC ERROR MESSAGE #57
SLOGIC ERROR MESSAGE #58
SLOGIC ERROR MESSAGE #59
SLOGIC ERROR MESSAGE #60
W2961
W2962
W2963
SLOGIC ERROR MESSAGE #61
SLOGIC ERROR MESSAGE #62
SLOGIC ERROR MESSAGE #63
A-12
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
W2964
W2965
W2966
W2967
W2968
W3800
W3801
W3802
W3803
W3804
W3805
W3806
W3807
W3808
W3809
W3810
W3811
W3812
W3813
W3814
W4000
W4001
W4002
W4500
W4501
W4502
W5000
W5001
W5002
W5003
W5004
W5005
W5006
Error Message
SLOGIC ERROR MESSAGE #64
The max load is XX of a permissible torque.
Load exceeded permissible torque.
Load exceeded max torque.
Please set a group number as XX.
Encoder battery voltage decrease.
Because the brake has been released, it is not possible to move.
Maint. period elapsed, maint. is required.
Total power ON time exceeded limit, maint. is required.
Total robot connection time exceeded limit, maint. is required.
Total servo ON time exceeded limit, maint. is required.
Total JtXX the total travel dist. exceeded limit, maint. is required.
Total times of MC ON exceeded limit, maint. is required.
Total times of servo ON exceeded limit, maint. is required.
Total times of E-stop exceeded limit, maint. is required.
JtXX total (curr)^3-motion dist. exceeded limit, maint. is required.
JtXX RMS value of current exceeded limit, maint. is required.
Power supply(1) for input to NO.XX I/O board is abnormal.
Power supply(2) for input to NO.XX I/O board is abnormal.
Power for output from NO.XX I/O board is abnormal or Fuse blown.
No response from PLC to Break down info writing.
Break down info cannot write on PLC[EC = XX].
Break down info writing cannot receive correct answer.
FIELD-BUS)Slave port OFFLINE.
FIELD-BUS)Master port OFFLINE.
CC-LINK)Data link error on Master board. XX
Release wait cond., in force measurement mode.
PLC communication error.
Weld controller XX not connected.
Weld controller XX no response.
Weld controller XX response error.
(Spot welding)No response from RWC XX.
(Spot welding)RWC response error XX.
W5007
W5008
W5009
(Spot welding)Weld fault XX.
(Spot welding)Cable disconnection error XX.
(Spot welding)Internal leak XX.
A-13
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
W5010
W5011
W5012
W5013
W5014
W5015
W5016
W6000
W6001
W6002
W6003
W6004
W6005
W6006
W6007
W6008
W6009
W6010
W6011
W7000
W7001
W7002
W7003
W7004
W7500
W7501
W8400
W8800
W8801
W8802
W8803
W8804
W8805
W8806
W8807
W8808
W8809
Appendix. Error Message List
Error Message
(Spot welding)Main cable exchange alarm XX.
(Spot welding)No connection with RWC XX.
Cannot achieve set force.
Tip wear over the limit. (MOVING SIDE)
Tip wear over the limit. (FIXED SIDE)
(Spot welding) Welding current has decreased.
Weld warning has arisen. (CodeXX)
Grease reduction gears and motor bearings.
Replace the robot main cable.
Replace the cooling fans in the controller.
Replace the DC power supply in the controller.
Replace the servo power unit.
Replace the power amplifier for the robot arm.
Replace the power amplifier for the robot wrist.
Replace the power amplifier for the traveller.
Exp interlock is disabled by jumper wiring.
Not selected Internal pressure Explosion-proof.
Disable Gun Relative Distance Check (ID:XX).
Shutter release signal variable logging error.
Cannot operate excluding the servo welding gun axis. Because the pressure
measurement mode.
Detected board gap quantity error.
Detected board gap quantity error.
The foreign body was detected in the Tip Dress.
Value of auto collect exceeds work abnormality level.
Can't continue check motion because separated from last pos.
Cannot execute a program because of LOW voltage.
Cannot achieve set force of JtXX.
Command value almost exceeds virtual safety fence.(SphereXX, LineXX)
Command value almost exceeds virtual safety fence.(SphereXX, ZUpper)
Command value almost exceeds virtual safety fence.(SphereXX, ZLower)
Command value almost invades restricted space.(SphereXX, Part.XX LineXX)
Command value almost invades restricted space.(SphereXX, Part.XX ZUpper)
Command value almost invades restricted space.(SphereXX, Part.XX ZLower)
Command value almost exceeds virtual safety fence.(ToolBox, LineXX)
Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
Command value almost invades restricted space.(ToolBox, Part.XX)
A-14
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
W8810
W8811
W8812
W8813
W8814
W8815
W8851
W8852
W8853
W8854
W8855
W8856
W8857
Error Message
Command value almost exceeds virtual safety fence.(LinkXX, LineXX)
Command value almost exceeds virtual safety fence.(LinkXX, ZUpper)
Command value almost exceeds virtual safety fence.(LinkXX, ZLower)
Command value almost invades restricted space.(LinkXX, Part.XX LineXX)
Command value almost invades restricted space.(LinkXX, Part.XX ZUpper)
Command value almost invades restricted space.(LinkXX, Part.XX ZLower)
Detected area interference.
Detected arm interference.(XX, XX)
ILL)Detected arm interference.(XX, XX)
ILL)Communication time out error.
ILL)Sequence processing demand completion waiting is time out error.
ILL)Sequence processing completion waiting is time out error.
ILL)Sequence processing system error.
W8858
W8859
W8860
W8900
E0001
E0002
E0100
E0101
E0102
E0103
E0104
E0105
E0106
E0107
E0108
E0109
ILL)Create/Set processing completion waiting is time out error.
ILL)Inter lock less function system error.
[ARM CONTROL b'd]Data received from IL server is invalid.
Can not operate because motion limitation signal was input.
Unknown error.
[Servo boardXX]CPU BUS error.
Abnormal comment statement exists.
Nonexistent label.
Variable is not defined.
Location data is not defined.
String variable is not defined.
Program or label is not defined.
Value is out of range.
No array suffix.
Divided by zero.
Floating point overflow.
E0110
E0111
E0112
E0113
E0114
E0115
E0116
E0117
String too long.
Attempted operation with neg. exponent.
Too complicated expression.
No expressions to evaluate.
SQRT parameter is negative.
Array suffix value outside range.
Faulty or missing argument value.
Incorrect joint number.
A-15
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E0118
E0119
E0120
E0121
E0900
E0901
E0902
E0903
E1000
E1001
E1002
E1003
E1004
E1005
E1006
E1007
E1008
E1009
E1010
E1011
E1012
E1013
E1014
E1015
E1016
E1017
E1018
E1019
E1020
E1021
E1022
E1023
E1024
Error Message
Too many subroutine calls.
Nonexistent subroutine.
No destination program.
Cannot specify the jump source program as jump destination.
Block step instruction check sum error.
Step data is broken.
Expression data is broken.
Check sum error of system data.
ADC channel error.
ADC input range error.
PLC interface error.
Built-in PLC is not installed.
INTER-bus board is not ready.
Spin axis encoder difference error.
Touch panel switch is short-circuited.
Power sequence board is not installed.
Second Power sequence board is not installed.
No.XX I/O board is not installed.
Power sequence detects error.
Built-in sequence board is not installed.
RI/O board or C-NET board is not installed.
INTER-BUS board is not installed.
Dual port memory for communication is not installed.
Amp Interface board is not installed.(Code=XX)
No.XX CC-LINK board is not installed.
PLC error.Error code is Hex.XX.
INTER-BUS status error.
Power sequence board for safety unit is not installed.
External equipment is abnormal.
Arm ID board error. (CodeXX)
Power sequence board error. (CodeXX)
Communication error in robot network.
EXT.AXIS release sequence error.(CodeXX)
E1025
E1026
E1027
EXT.AXIS connect sequence error.(CodeXX)
Main CPU ID mismatch.
Safety circuit was cut OFF.
A-16
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1028
E1029
E1030
E1031
E1032
E1033
E1034
E1035
E1036
E1037
E1038
E1039
E1040
E1041
E1042
E1043
E1044
E1045
E1046
E1047
E1048
E1049
E1050
E1051
E1052
E1053
E1054
E1055
E1056
E1057
E1058
E1059
E1060
Error Message
JtXX motor overloaded.
Encoder rotation data is abnormal.(JtXX)
Encoder data is abnormal.(JtXX)
Miscount of encoder data.(JtXX)
Mismatch ABS and INC encoder data(JtXX).
Encoder line error of (JtXX).
Encoder initialize error (JtXX).
Encoder response error(JtXX).
Encoder communication error.(JtXX)
Encoder data conversion error.(JtXX)
Encoder ABS-track error.(JtXX)
Encoder INC-pulse error.(JtXX)
Encoder MR-sensor error. (JtXX)
Limit switch (JtXX) is ON.
Limit switch signal line is disconnected.
Teach Plug is abnormal.
Destination position is out of the specified area.
(Spot welding)Gun-clamp mismatch.
Too short distance between start point and end point.
Axis number is not for conveyor follow mode.
Offset data of zeroing is illegal value.
Current position is out of the specified area.
Encoder and brake power off signal not dedicated.
Incorrect double OX output.
Work sensing signal is not dedicated.
Work sensing signal already input.
Cannot execute motion instruction.
Start point position error for circle.
MASTER robot already exists.
Check to which robot MASTER/ALONE were instructed.
SLAVE robot already exists.
Not an instruction for cooperative motion.
Cannot execute in check back mode.
E1061
E1062
E1063
Cannot execute in ONE program.
Jt2 and Jt3 interfere during motion to start pose.
Jt2 and Jt3 interfere during motion to end pose.
A-17
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1064
E1065
E1066
E1067
E1068
E1069
E1070
E1071
E1072
E1073
E1074
E1075
E1076
E1077
E1078
E1079
E1080
E1081
E1082
E1083
E1084
E1085
E1086
E1087
E1088
E1089
E1090
E1091
E1092
E1093
E1094
E1095
E1096
Error Message
Illegal pallet number.
Illegal work number.
Illegal pattern number.
Illegal pattern type.
Illegal work data.
Illegal pallet data.
ON/ONI signal is already input.
XMOVE signal is already input.
Home position data is not defined.
Illegal timer number.
Over maximum signal number.
Illegal clamp number.
Cannot use negative time value.
No value set.
Illegal signal number.
Cannot use dedicated signal.
Not RPS mode.
Cannot use negative value.
Out of absolute lower motion range limit.
Out of absolute upper motion range limit.
Out of set lower motion range limit.
Out of set upper motion range limit.
Start point for JtXX beyond motion range.
End point for JtXX beyond motion range.
Destination is out of motion range.
Cannot do linear motion in current configuration.
External modulation data is not input.
External modulation data is abnormal.
Modulation data is over limit.
Incorrect motion instruction to execute modulate motion.
Illegal joint number.
Cannot execute motion instruction in PC program.
Incorrect auxiliary data settings.
E1097
E1098
E1099
Missing C1MOVE or C2MOVE instruction.
C1MOVE(CIR1)instruction required before C2MOVE.
Unable to create arc path, check positions of the 3 points.
A-18
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1100
E1101
E1102
E1103
E1104
E1105
E1106
E1107
E1108
E1109
E1110
E1111
E1113
E1114
E1115
E1116
E1117
E1118
E1119
E1120
E1121
E1122
E1123
E1124
E1125
E1126
E1127
E1128
E1129
E1130
E1131
E1132
E1133
Error Message
Cannot execute in sealing specification.
Can only execute in sealing specification.
Option is not set, cannot execute.
Over conveyer position.
Too many SPINMOVE instructions.
Start/Destination point is in protected space.
Cannot execute in this robot.
Cannot use SEPARATE CONTROL.
Duplicate robot network IDs.
Conveyor I/F board is not installed.
GROUP is not primed.
Due to motion restriction, JtXX cannot move.
Work sensing signal is not detected.
Interruption in cooperative control.
Forced termination of cooperative control.
Spin axis is not stopped on every 360 degrees.
Process time over.
Command value for JtXX suddenly changed.
Command value for JtXX beyond motion range.
Current command causes interference betw Jt2 and Jt3.
Other robot is already in the interference area.
Unexpected motor power OFF.
Speed error JtXX.
Deviation error of JtXX.
Velocity envelope error JtXX.
Command speed error of JtXX.
Command acceleration error of JtXX.
Uncoincidence error betw destination and current JtXX pos.
External axis JtXX moved while holding them.
JtXX collision was detected.
JtXX unexpected shock is detected.
Motor power OFF. Measurement stopped.
Conveyor has reached max. value position.
E1134
E1135
E1136
Abnormal work transfer pitch of conveyor.
Motor power OFF.
Standard terminal is not connected.
A-19
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1137
E1138
E1139
E1140
E1141
E1142
E1143
E1144
E1145
E1146
E1147
E1148
E1149
E1150
E1151
E1152
E1153
E1154
E1155
E1156
E1157
E1158
E1159
E1160
E1161
E1162
E1163
E1164
E1165
E1166
E1167
E1168
E1169
Error Message
Cannot input/output to teach pendant.
Aux. terminal is not connected.
DA board is not installed.
No conveyor axis.
Conveyor transfers beyond sync. zone.
No traverse axis.
Conveyor axis number is not set.
No Arm control board.
Cannot use specified channel, already in use.
[LSEQ]Aborted by processing time over.
Cannot open setting file, so cannot set to shipment state.
Cannot read setting file, so cannot set to shipment state.
Cannot open setting data, so cannot set to shipment state.
Cannot read setting data, so cannot set to shipment state.
Too much data for setting to the shipment state.
Name of setting data for shipment state is too long.
Power sequence board detected error.(Code=XX)
Option SIO port not installed.
A/D converter is not installed.
[ARM CONTROL BOARD]Processing time over.
Arm ID I/F board error. (CodeXX)
(SSCNET)Servo error in JtXX.
(SSCNET)Error code for servo is (XX).
(SSCNET)Servo error and monitor setting error of JtXX.
Automatic Tool Registration not supported by robot model.
Buffer overflow occurred in the gravity comp. value channel XX.
Robot stopped in checking operational area.
[LSEQ]Program execution error at control power ON.(CodeXX)
Unable to download ext. axis parameter.(Jt-A)
Num. not assigned to specified channel.(Jt-A)
Unable to download ext. axis parameter.(Jt-B)
Num. not assigned to specified channel.(Jt-B)
Error in servo parameter change sequence.(CodeXX)
E1170
E1171
E1172
Slave is not ready.
CC-LINK communication board is not installed.
Weld communication board is not installed.
A-20
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1173
E1174
E1175
E1176
E1177
E1178
E1179
E1180
E1181
E1182
E1183
E1184
E1185
E1186
E1187
E1188
E1189
E1190
E1191
E1192
E1193
E1194
E1195
E1196
E1197
E1198
E1199
E1200
E1201
E1202
E1203
E1204
E1205
Error Message
Servo communication error JtXX.
AD board No.0 is not installed.
Offset data of zeroing is illegal value.(RobotXX)
(SSCNET)Download error of external axis parameter.
(SSCNET)Joint number is not assigned to the channel.
Communication error between Arm Control and Arm I/F board.
The current under bending compensation is too large.(JtXX)
Download error of external axis parameter.(JtXX)
Encoder battery low voltage.[Servo(XX)]
Encoder battery low voltage.[External axis(XX)]
Because Jt5 is not zero degree, cannot move along straight line.
Illegal configuration for motion.
Jt1 and Jt2 is interfered at start location.
Jt1 and Jt2 is interfered at end location.
Current command between Jt1 and Jt2 is interfered.
(SSCNET)Error in servo parameter change sequence.(CodeXX)
(SSCNET)Regenerative error of JtXX.(CodeXX)
(SSCNET)Speed error of JtXX.(CodeXX)
(SSCNET)Motor overload of JtXX.(CodeXX)
(SSCNET)Deviation error of JtXX.(CodeXX)
(SSCNET)Encoder battery of JtXX is low voltage.(CodeXX)
(SSCNET)Parameter warning of JtXX.(CodeXX)
(Dual servo)Deviation error between master joint and slave joint.
While lifter is locked, it cannot move.
Compensation LS signal is not dedicated.
Brake check sequence error.
Brake check function is not supported by servo software ver.
(Dual servo)Cannot compensate current error (deviation XX).
Interference check board is not installed.
Voice recorder cannot stop.
LS location is not registered.
Current stretch over the limit.
Total stretch over the limit.
E1207
E1208
E1209
The type of I/O board on arm ID board is wrong.
Download error of servo parameter.(JtXX)
Upload error of servo parameter.(JtXX)
A-21
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1210
E1211
E1212
E1213
E1214
E1215
E1216
E1217
E1218
E1219
E1220
E1221
E1222
E1223
E1224
E1225
E1228
E1229
E1230
E1231
E1232
E1233
E1234
E1235
E1236
E1237
E1238
E1239
E1240
E1241
E1242
E1243
E1244
Error Message
Cannot execute program because unprotected.
Because the memory was full, could not copy the program.
Because the memory was full, the copy of program was suspended.
Jt4 and robot arm interfere during motion to start pose.
Jt4 and robot arm interfere during motion to end pose.
Current command causes interference between Jt4 and robot arm.
Jt5 and Jt6 interfere during motion to start pose.
Jt5 and Jt6 interfere during motion to end pose.
Current command causes interference between Jt5 and Jt6.
Exceeds allowable No. of output instructions for the path.
Signal output point is out of the path.
Too many signal numbers are specified.
Motion instruction to start/end point of path not set.
No pose data in last/next motion instruction.
Several signal output points detected at the same point.
Correction end instruction is missing.
Jt4 value in the start point is not 0 degree.
Jt4 value in the target point is not 0 degree.
Flange faces direction of upper sphere in start point.
Flange faces direction of upper sphere in target point.
Option CPU board is not installed.
IJoint/ILinear signal not specified.
IJoint/ILinear signal not detected.
Separate control I/O board is not installed.
Distance is too long to correct.
Vision recognition error.
Vision communication error.
Cannot use this instruction in frame correction mode.
BASE FRAME is not sent from vision unit.
Improper parameter for FN481.
Cannot create more than 99 BASE FRAME.
Cannot execute because cameraXX is disconnected.
Jt1 and Jt2 and floor interfere during motion to start pose.
E1245
E1246
E1247
Jt1 and Jt2 and floor interfere during motion to end pose.
Current command causes interference between Jt1, Jt2 and floor.
Calculation of encoder absolute data is not completed.(JtXX)
A-22
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1248
E1249
E1250
E1251
E1252
E1253
E1254
E1255
E1256
E1257
E1258
E1259
Error Message
EEPROM access flag in encoder is busy.(JtXX)
Temperature in encoder is over the limit.(JtXX)
Rotation speed of encoder is over the limit.(JtXX)
EEPROM access error occurred in encoder.(JtXX)
Encoder rotation data (internal) is abnormal.(JtXX)
Uncoincidence error between request and response in encoder. (JtXX)
Cannot operate because a MC of a group XX is off.
The motor power of unchosen robot was turned on.
Internal valve , sensor and error reset I/F board missing.
MC of groupXX turned off during individual repeat operation.
MC turned off during operation.
Invalid Structure of palletizing instruction.
E1260
E1261
E1262
E1263
E1264
E1267
E1268
E1269
E1270
E1271
E1272
E1273
E1274
E1275
E1276
E1277
E1278
E1279
E1280
E1281
E1282
E1283
E1284
E1285
E1286
Cannot execute instruction during palletizing motion.
Palletising motion aborted.
Encoder rotation speed exceeded limit. (JtXX)
Encoder temperature exceeded limit. (JtXX)
Velocity envelope error in endless rotation axis.(JtXX)
The initial setting of Encoder is abnormal. (JtXX)
Breakage in the encoder line or faulty setting of encoder baud rate. (JtXX)
The program is for other robot.
The pose variable is for other robot.
Interference between arm and floor at start pose.
Interference between arm and floor at end pose.
Command causes interference between arm and floor.
JtXX Over speed in heavy load mode.
JtXX Beyond the motion range in heavy load mode.
Start point JtXX is beyond the motion range in heavy load mode.
End point JtXX is beyond the motion range in heavy load mode.
Can't slant wrist any more.
Wrist does not face vertically down at start point.
Wrist does not face vertically down at end point.
Command to Jt4 over limit.
Cannot operate because a MC of a groupXX(JtXX) is off.
analysis)The E1035 error occurs frequently.JtXX
analysis)The E1035 and E1029 error occur at the same time.JtXX
analysis)The E1035 and E1036 error occur at the same time.JtXX
analysis)The E1035 and E1032 error occur at the same time.JtXX
A-23
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
E1287
E1288
E1289
E1290
E1291
E1292
E1293
E1294
E1295
E1296
E1297
E1298
E1299
E1300
E1301
E1302
E1303
E1304
E1305
E1306
E1307
E1308
E1309
E1310
E1311
E1312
E1313
E1314
E1315
E1316
E1317
E1318
E1319
E1321
E1322
E1323
E1324
Appendix. Error Message List
Error Message
Power module error JtXX (UPPER).
Power module error JtXX (LOWER).
[Servo boardXX]Synchronous error.(Servo FPGA)
JtXX Voltage of the current sensor exceeded the upper limit.
JtXX Current sensor is disconnected or out of order.(U)
[Servo boardXX]Abnormal signal input from MCXX.
[Servo boardXX]Current feedback gain is abnormal.
[Servo boardXX]I/O 24V is low.
[Servo boardXX]24V for internal valve is low.
[Servo boardXX]Mismatch in safety circuit LS conditions.
[Servo boardXX]Mismatch in jumper wiring for detecting internal pressure.
[Servo boardXX]Mismatch in contact condition of LS override switches.
[Servo boardXX]Jumper wiring for detecting internal pressure is disconnected.
[Servo boardXX]DC 24V is abnormal.
[Servo b’dXX]Encoder type mismatch between software and servo board.
[MCXX]OFF check is abnormal.(Servo boardXX)
[MCXX]OFF check of safety relay is abnormal.(Servo boardXX)
[MCXX]Incorrect operation of K1.(Servo boardXX)
[MCXX]Incorrect operation of K2.(Servo boardXX)
[MCXX]Incorrect operation of inrush current control relay.(Servo boardXX)
[MCXX]Incorrect operation of safety relay KS1.(Servo boardXX)
[MCXX]Incorrect operation of safety relay KS2.(Servo boardXX)
[MCXX]Incorrect operation of safety relay KS3.(Servo boardXX)
[MCXX]Incorrect operation of motor ON relay.(Servo boardXX)
[MCXX]Incorrect operation of safety circuit motor OFF relay.(Servo boardXX)
[MCXX]Mismatch in safety circuit motor OFF relay.(Servo boardXX)
[MCXX]Mismatch in individual MC control of safety circuit.(Servo boardXX)
[MCXX]Thyristor Thermal is abnormal.(Servo boardXX)
Watchdog error in NoXX I/O board.
[I/O board(No.XX)]Access Error.[Address:XX][Code:XX]
[Servo Board(NoXX)]Response from monitor is abnormal. [Code:XX]
[MCXX]DC 20V is abnormal.(Servo boardXX)
Internal valve, sensor and error reset I/F board No.2 is not installed.
[Main CPU board]Servo board(XX) communication error. (CodeXX)
Setting num. of safety circuits differs betw. powerseq.b'd and MCXX. (Servo
b'dXX)
Setting num. of safety circuits differs betw. servo b'dXX and MCXX.
Safe circuit disconnected between power sequence board and servo boardXX.
A-24
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
E1325
E1326
E1327
E1328
E1329
E1330
E1331
E1332
E1333
E1334
E1335
E1336
E1337
E1338
E1339
E1340
E1341
E1342
E1343
E1344
E1345
E1346
E1347
E1348
E1349
E1350
E1351
E1352
E1353
E1354
E1355
E1356
E1357
E1358
E1359
Appendix. Error Message List
Error Message
Safe circuit disconnected between servo boardXX and MCXX.
Safety fence is open.
[Power sequence board]Miscompare in motor off relay condition on safety
circuit.
[Power sequence board]Error of motor off relay on safety circuit.
[Power sequence board]Error in TEACH/REPEAT switch on safety circuit.
[Power sequence board]IO 24V is low.
[Power sequence board]Thermal error.
[Power sequence board]Power error signal was input from servo boardXX.
Motor power ON signal has turned off.(Servo boardXX)(MCXX)
TEACH/REPEAT switch is abnormal.(Mode differs betw. safety circuit and
monitor.)
Unexpected motor powerOFF.(Servo boardXX)(MCXX)
[Servo boardXX]Communication error with Main CPU board.
[MCXX]Brake power is abnormal.(Servo boardXX)
[MCXX]P-N low voltage.(Servo boardXX)
[MCXX]P-N high voltage.(Servo boardXX)
[MCXX]Regenerative time over.(Servo boardXX)
[MCXX]Regenerative resistor overheat.(Servo boardXX)
Motor harness disconnected or robot temperature exceeded limit.(MCXX)
Mismatch betw connected place of brake harness and software setting. (JtXX)
JtXX Current sendor is disconnected or out of order.(V)
[Servo boardXX]Limit switch signal line is disconnected.
JtXX Failed to get encoder full data.
[MCXX]Destination spec is incorrect.(Servo boardXX)
[MCXX]Robot arm spec/separate control spec is incorrect. (Servo boardXX)
[MCXX]Explosion proof setting is mismatch.(Servo boardXX)
[MCXX]MC specification error.[CodeXX](Servo boardXX)
[MCXX]MC OFF delay specification is incorrect.(Servo boardXX)
JtXX Codes set in software and power block do not match.
[Main CPU board]CPU temperature is abnormal.
[Main CPU board]Temperature in CPU board exceeded the limit.(XX 1/1000
deg C)
Error in servo I/F command communication.(Code:XX)
The tool shape is not set.
Failed to download ext. axis parameter data.(Jt-C)
Axis No. is not assigned to the specified channel.(Jt-C)
JtXX axis U phase overcurrent.
A-25
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E1360
E1361
E1362
E1363
E1364
E1365
E1366
E1367
E3800
E3801
E3802
E3803
Error Message
JtXX axis V phase overcurrent.
JtXX axis W phase overcurrent.
[Servo boardXX]Speed of tool center point exceeded safety speed.
[Servo boardXX]Speed of flange center point exceeded safety speed.
[ARM CONTROL BOARD]Out of command synch, between IF and SV.
TEACH KEY SWITCH is ON in two or more places.
Watchdog error in NoXX ANYBUS interface board.
Improper parameter for KI481.
JtXX axis amp servo amp heating.
JtXX axis amp main circuit power supply decrease.
Encoder harness disconnected. JtXX
JtXX axis amp speed control error.
E3804
E3805
E3806
E3807
E3808
E3809
E3810
E3811
E3900
E4000
E4001
E4002
E4003
E4004
E4005
E4006
JtXX axis amp velocity feedback error.
JtXX axis amp position envelope error.
JtXX axis amp servo ready does not turn on.
JtXX axis amp IPM overheated.
Motor power OFF (EXT_EMG).
Brake release signal error.
Power sequence ready off.
JtXX axis amp command value suddenly changed.
Mismatch moving tool data and selected tool data.
Data communication error.
Data reading error.
Data write error.
Unexpected error in file access.
Communication retry error.
Communication process was stopped.
Receive no data after request.
E4007
E4008
E4009
E4010
E4011
E4012
E4013
E4014
Receiving data is too long(MAX=255 characters).
Abnormal data (EOT) received in communication.
Communication time out error.
Terminal already in use.
Communication port already in use.
Waiting for input of PROMPT. Connect input device.
TELNET)SEND error. Code=XX
TELNET)RECV error. Code=XX
A-26
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
E4015
E4016
E4017
E4018
E4019
E4020
E4021
E4022
E4023
E4024
E4025
E4026
E4027
E4028
E4029
E4030
E4031
E4032
E4033
E4034
E4035
E4036
E4037
E4050
E4051
E4052
E4053
E4054
E4055
E4056
E4057
E4058
E4059
E4060
E4061
E4062
Appendix. Error Message List
Error Message
TELNET)IAC receive error. Code=XX
TELNET)Close failure. Code=XX
TELNET)Main socket close failure. Code=XX
TELNET)System error. Code=XX
TCPIP)Socket open failure. Code=XX Dst.IP=XX.XX.XX.XX
TCPIP)Socket close failure. Code=XX Dst.IP=XX.XX.XX.XX
TCPIP)Communication Error. Code=XX Dst.IP=XX.XX.XX.XX
TCPIP)Message is too long.
TCPIP)Cannot reach the Host.
TCPIP)Communication Time Out. Dst.IP=XX.XX.XX.XX
TCPIP)Connection aborted.
TCPIP)No Buffer Space.
TCPIP)Bad Socket.
FTP)Data receive error.(Code=XX)
FTP)Data send error.(Code=XX)
FTP)Server does not recognize command.(Code=XX)
FTP)Failed to disconnect with FTP server.(Code=XX)
FTP)Unregistered OS detected.
FTP)Failed to connect with server.(Code=XX)
FTP)Failed to receive HOST OS information.(Code=XX)
FTP)TCP/IP not initialized.
FTP)FTP service busy now.
FTP)Failed AUTO-SAVing.
No response from the FDD/PC_CARD driver board.
No communication with FDD/PC_CARD driver board.
[FDD/PC_CARD]Failed to set verify function. Please set again.
Channel error.
TCPIP)Cannot execute because Ethernet board not installed.
TCP)Cannot create a socket.
TCP)This port is not in LISTEN (SOCK).
TCP)Illegal Socket ID.
Failed download to FDD/PC_CARD driver board.
ASCYCLE communication receive error.(Code:XX)
[ARM CONTROL BOARD]ASCYCLE communication receive
error.(Code:XX)
Received gauge hole data exceeds allowable range.
Master/slave data is not registered.
A-27
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
E4063
E4064
E4065
E4066
E4067
E4068
E4069
E4070
E4071
E4072
E4073
E4074
E4075
E4076
E4077
E4078
E4500
E4501
E4510
E4511
E4512
E4520
E4521
E4522
E4523
E4524
E4525
E4526
E4527
E4528
E4529
E4530
E4531
E4532
E4533
E4534
Appendix. Error Message List
Error Message
Reference point data is not registered.
3D calibration/measurement modes are both ON.
Unregistered variable specified to receive data.
Variable specified to receive data is broken.
Received data is broken.
Start code is not correct.
End code is not correct.
3D camera group No. not specified.
Incorrect 3D camera group No.
Communication beginning wait time out error.
No servo off signal from ARM I/F board.
[Servo boardXX]No response from MCXX.(Code:XX)
[Servo boardXX]Error in communication with MCXX.(Code:XX)
[MCXX]Servo boardXX communication error.(Code:XX)
[Servo boardXX]Error in communication with main CPU board.(Code:XX)
[Servo boardXX]Error in command communication with the main CPU
board.(Code:XX)
ANYBUS)IN-AREA request timeout.XX
ANYBUS)OUT/FB.CTRL release timeout.XX
DN)Master status.XX
DN)Node status.XX
ABM-DN)Mailbox error.
ABMA-PDP)Status STOP.XX
ABMA-PDP)Status OFFLINE. XX
ABMA-PDP)I/O data Communication error.XX
ABMA-PDP)Sending of timed out I/O data.XX
ABMA-PDP)Timeout of receiving I/O data.XX
ABMA-PDP)Timeout of sending message.XX
ABMA-PDP)Timeout of receiving message.XX
ABMA-PDP)Check configuration data.XX
PROFIBUS)Slave Diag-error response detected.XX
PROFIBUS)Statistic counter-error response detected.XX
DN)DeviceNet cable is disconnected.
CC-LINK)Communication has been disconnected. XX
CC-LINK)Initial condition setting is incorrect.
CC-LINK)Watch dog timeout error.
CC-LINK)Parameter setting error. XX
A-28
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E4535
E4536
E4537
E4538
E5000
E5001
E5002
E5003
E5004
E5005
E5006
E5007
E5008
E5009
E5010
E5011
E5012
E5013
E5014
E5015
E5016
E5017
E5018
E5019
E5020
E5021
E5022
E5023
E5024
E5025
E5026
E5027
E5028
Error Message
CC-LINK)Time out on setting parameter.
CC-LINK)Master board is abnormal. XX
CC-LINK)Initialization error on master board . XX
CANopen)Network is disconnected.
Connected permission signal has not been turned ON.
RWC type is not process control type.
1GS board is not process control type.
Illegal extend (retract) output signal.
Weld completion signal already input.
(Spot weld)Weld schedule setting data is abnormal.
CLAMP SPEC is not set as PULSE.
Servo weld gun not connected or wrong gun connected.
Tip wear measurement (STAGE1) was not executed.
Work sensing signal(gun_tip touch signal) is not set.
Servo weld gun mechanical parameter is not set.
This clamp number already set for servo weld gun axis.
Cannot change the gun because offset data is abnormal.
Cannot change multiple guns at the same step.
Cannot execute, gun connected to another joint.
Gun status data disagrees with clamp condition.
Data of SRVPRESS is wrong.
Wear base data is not registered.
Weld completion signal has not been detected.
Weld fault signal is detected.
Retract pos. monitor error.
Extend pos. monitor error.
Current gun retract position differs from a destination.
Wear is abnormal, cannot take measurement.
Pressurization comp. signal has not been detected.
Gun opening comp. signal has not been detected.
(Spot welding)RWC error. XX
Robot stopped in welding.
Cannot achieve set force.
E5029
E5030
E5031
Gun tip stuck.
Copper plate wear exceeds limit. step=XX
Weld completion signal is not turned OFF.
A-29
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E5032
E5033
E5034
E5035
E5036
E5037
E5038
E5039
E5040
E5041
E5042
E5043
E5044
E5045
E5046
E5047
E5048
E5049
E5050
E5051
E5052
E5053
E5054
E5055
E5056
E5057
E5058
E5059
Error Message
Calibration did not end normally.
Cannot weld because of abnormal thickness.
Tip wear exceeds limit. (MOVING SIDE)
Tip wear exceeds limit. (FIXED SIDE)
Incorrect gun status data.
Tip wear exceeds limit. XX
Arc detection signal did not turn OFF.
No response from RWC communication I/F board.
Cannot connect gun because gun is already connected.
Cannot disconnect gun because gun is already disconnected.
Gun No is not defined or Gun type is not servo gun.
Communication error in welder. (CodeXX)
Failed to get weld data. (timer XX)
Failed to change weld data. (timer XX)
Weld error has arisen.
Receiving weld items now, wait till completion.
Weld controller is unconnected or weld items are not received. (timer XX)
Serial number signal error.
This welder is without Traceability.
Cannot calibrate because tool change axis is disconnected.
The pressurizing power measurement value is abnormal.
The pressurizing power sensor is disconnected or it breaks down.
The selector switch on TP is set to manual operation.
The selector switch on TP is set to automatic operation.
No Initialization Weld board.
Initialization failure in Initialization Weld board.
Welder(DENGEN COMPANY) not connected. (welder XX)
Welder(DENGEN COMPANY) response error. (welder XX)
E5060
E5061
E5062
E5063
E5064
E5065
E5066
E5067
E5500
Initialization Weld board protected. (welder XX)
Welder(DENGEN COMPANY) data process not execute. (welder XX)
Welder(DENGEN COMPANY) data process error.(welder XX)
Weld error has arisen. (CodeXX)
Welder(DENGEN COMPANY) of weld was aborted. (welder XX)
Welder(DENGEN COMPANY) error has arisen. (welder XX)
Waiting weld completion time out.(welder XX)
Magnet control is abnormal.(welder XX)
Vision board is not installed.
A-30
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E5501
E5502
E5503
E5504
E5505
E5506
E5507
E5508
E5509
E5510
E5511
E5512
E5513
E5514
E5515
E5516
E5517
E5518
E5519
E5520
E5521
E5522
E5523
E5524
E5525
E5526
E5527
E5528
E5529
E5530
E5531
E5532
E5533
Error Message
(Vision)Camera not connected.
(Vision)Incorrect parameter.
(Vision)Incorrect Symbol.
(Vision)Incorrect name.
(Vision)Incorrect image memory.
(Vision)Incorrect histogram data.
(Vision)Incorrect mode.
(Vision)Incorrect density(/color).
(Vision)Incorrect camera input assignment.
(Vision)Incorrect camera ch.number.
(Vision)Incorrect Window No.
(Vision)Incorrect coordinates data.
(Vision)Incorrect number.
(Vision)Incorrect image code(binary/multi).
(Vision)Incorrect threshold.
(Vision)PROTO(/TEMPLATE) not registered or already exists.
(Vision)Cal. data not registered.
(Vision)Graphic cursor is not initialized.
(Vision)Too many samples from PROTO object.
(Vision)Too many targets detected.
(Vision)Vision command not initiated.
(Vision)System registered with abnormal data.
(Vision)Error in processing image(s).
(Vision)Sound port assigned another function.
(Vision)Lack of data storage area.
(Vision)Incorrect synch. mode.
(Vision)Vision processing now.
(Vision)Image capture error.
(Vision)Time out or Buffer overflow.
(Vision)Failed to write on flash memory.
(Vision)Proto data abnormal, so initialized.
(Vision)Work detection failure.
(Vision)Initialization error. Code = XX
E5534
E5535
E5536
(Vision)Vision system error.
(Vision)Specified motion mode is incorrect.
(Vision)Inappropriate camera/projector parameters.
A-31
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E5537
E5538
E5539
E5540
E5541
E5542
E5543
E5544
E5545
E5546
E5547
E5548
E5549
E5550
E5551
E6000
E6001
E6002
E6003
E6004
E6005
E6006
E6007
E6008
E6009
E6010
E6011
E6012
E6013
E6014
E6015
E6016
E6017
Error Message
(Vision)Incorrect camera switch assignment.
(Vision)This plane is assigned to another camera.
(Vision)Edge was not found.
(Vision)Inappropriate HSI data.
(Vision)H data range width is over 128.
(Vision)Distance image input unit not set for camera.
(Vision)Cannot calculate the set edge points.
(Vision)Check color conversion table type in set config.
(Vision)Incorrect area size.
(Vision)Slit image does not exist.
(Vision)Incorrect no. of correlation vectors.
(Vision)Inappropriate vector data.
(Vision)X-Fit environment was not set.
(Vision)Mouse is not initialized.
(Vision)Camera switcher board is not installed.
Explosion proof teach pendant is not connected.
Step after XD(2)START must be LMOVE or HMOVE.
Signal condition already input.
Door open detect signal is not dedicated.
Location data was not detected.
Incorrect setting of barrier unit.
Signal not detected.
Wrist can't be straightened any more (Singular point 1).
Wrist can't be bent any more (Singular point 2).
Purge air flow is insufficient.
Out of XYZ MOVING AREA LIMIT.
Pressure within enclosure is low.
Relative distance between guns is too near (ID:XX).
No free memory in program queue.
No free memory in delayed start queue.
Special signal is not specialized.
Robot arm stretching out (Singular Point 3).
Out of mechanical XYZ motion limits.
E6018
E6019
E6020
Painting equipment control board error. (CodeXX)
Painting equipment control board is not installed.
Monitoring Robot ID is duplicate.
A-32
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
E6021
E6022
E6023
E6024
E6025
Appendix. Error Message List
E6026
E6027
E6028
E6029
E6030
E6031
Error Message
(Mutual-Wait)There is no response from the other party robot.
Duplicate Mutual-Wait IDs.
(Mutual-Wait)Communication error in Mutual-Wait.
Wrist can't bend any further left/right (Singular Point 1).
(Conveyer synchronous communications)It is a conveyer position reception
error.
Guns are too near in X direction. (ID:XX)
Guns are too near in Y direction. (ID:XX)
Guns are too near in Z direction. (ID:XX)
[Servo boardXX]Mismatch in internal pressure in safety circuit.
[Servo boardXX]Pressure within enclosure is low.
Monitoring Robot ID is invalid.
E6032
E6033
E6034
E6500
E6501
E6502
E6503
E6504
E6505
E6506
E6507
E6508
E6509
E6510
E6511
E6512
[Purge control board]Pressure within enclosure is low.
Painting equipment control process error. (CodeXX)
Cartridge table rotate command is abnormal.
No welding Interface board.
No.2 welding Interface board not found.
Arc failure.
Wire stuck.
Arc start failure.
Arc weld insulation defect.
Torch interference.
Illegal interpolation data.
No D/A board for polarity ratio control.
No work detected.
Undefined sensing direction.
Insufficient num. of sensing points.
Undefined mother or daughter work.
E6513
E6514
E6515
E6516
E6517
E6518
E6519
E6520
E6521
Too many sensing points.
Work specification incorrect.
Incorrect sensing point specified.
Wire check failure.
Incorrect weld condition number.
No weld condition data set.
Weld condition data is out of range.
Laser sensor tracking value exceeded.
Beyond Laser sensor tracking ability.
A-33
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E6522
E6523
E6524
E6525
E6526
E6527
E6528
E6529
E6530
E6531
E6532
E6533
E6534
E6535
E6536
E6537
E6538
E6539
E6540
E6541
E6542
E6543
E6544
E6545
E6546
E6547
E6548
E6549
E6550
E6551
E6552
E6553
E6554
Error Message
Laser sensor cannot detect welding joint.
Calibration data between torch and camera is not ready.
Error in data calculated using Laser sensor.
Cannot detect weld joint, Laser sensor tracking set already.
No response from Laser sensor controller.
Laser sensor communication error. Code is XX.
Start point not found by Laser sensor.
Finish point not found by Laser sensor.
Cannot use circular interp. with Laser sensor function.
Cannot turn Laser ON because motor power is OFF.
No communication board to Laser sensor.
No RTPM board.
Too many taught points for RTPM.
RTPM arc sensor error.
RTPM current deviation error.
RTPM tracking value is out of range.
Beyond RTPM tracking ability.
AVC tracking value is out of range.
Beyond AVC tracking ability.
No AVC board.
AVC voltage deviation error.
Too many taught points for AVC.
Hyper Arc tracking value is out of range.
Beyond Hyper Arc tracking ability.
Bead end is not found.
Finish end is not found.
Hyper Arc revolution beyond normal deviation.
Hyper Arc torch calibration error.
Hyper Arc Z phase index error.
No Hyper Arc board.
Hyper Arc board error. Code is XX.
Hyper Arc current sensor error.
Hyper Arc voltage sensor error.
E6555
E6556
E6557
Hyper Arc current deviation error.
Hyper Arc amplifier error. Code is XX.
No Wire feeding Control board.
A-34
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E6558
E6559
E6560
E6561
E6562
E6563
E6564
E6565
E6566
E6567
E6568
E6569
E6570
E6571
E6572
E6573
E6574
E6575
E6576
E6577
E6578
E6579
E7000
E7001
E7002
E7003
E7004
E7005
E7006
E7007
E7008
E7009
E7500
Error Message
Wire feeding control error, code is XX.
Wire feeding speed deviation error.
Cannot re-calibrate weld in progress.
Cannot weld, re-calibration in progress.
Electric pole stuck.
KHITS tracking system error. (Code = XX)
The arc weld instruction sequence is incorrect.
Arc welding Interface board(1LN) is not installed.(robot XX)
FN instructions not executed in the correct order.
KLS tracking system error.(Code=XX)
Failed in executing command to tracking system.(cmd=XX)
Taught data exceeds inclination limit for compensation.
Cannot execute because welding now.
Cannot execute because wire inching/retracting now.
Teach point for circular motion is missing.
The welding machine is abnormal.(Code=XX)
Sensing of groove: cannot detect edge.
Sensing of groove: gap error.
Welder is not ready for operation. (Code=XX)
Deviation is too large. Reset allows non-correction movement.
Sensing was interrupted due to power OFF. Restore step and retry.
KI instructions not executed in the correct order.
Servo weld gun disconnected.
Location data includes released gun status data.
Destination is far from target point.
The clearance distance of gunXX is set to 0mm.
Gun tip wear change over the limit. (MOVING SIDE)
Gun tip wear change over the limit. (FIXED SIDE)
Clamp number or gun number is not servo weld gun.
Cannot change tip base data in 1 Stg. because tip wear rate is not set.
Independent Gun control is not completed.
Current limit for servo welding gun is abnormal.
JtXX Collision is detected.
E7501
E7502
E7503
JtXX Unexpected shock is detected.
AC Fail Process Error = XX
POWER SEQUENCE setting data incorrect.
A-35
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E7504
E7505
E7506
E7507
E7508
E7509
E7510
E7511
E7512
E7513
E7514
E8200
Error Message
Angle between JtXX is out of range at start location.
Angle between JtXX is out of range at end location.
Angle between JtXX is out of range.
SC1MOVE or SC2MOVE instruction is required after SC1MOVE.
SC1MOVE instruction is required before SC2MOVE.
Cannot execute, interpolation conditions are not fulfilled.
Cannot move with current posture.
Brake control bit number is duplicated.
L3C1MOVE or L3C2MOVE instruction is required after L3C1MOVE.
L3C1MOVE instruction is required before L3C2MOVE.
Specified parameter is not consistent.
Not in cooperative mode.
E8201
E8202
E8203
E8204
E8205
E8206
E8207
E8208
E8209
E8210
E8211
E8212
E8213
E8214
E8400
E8401
Unmatch the total of motion instruction in cooperative mode.
Unmatch step of motion instruction in cooperative mode.
Cannot use this instruction in cooperative mode.
Invalid cooperative group No.
No JMASTER robot.
TouchSensing in Cooperative mode is no supported.
JMASTER robot already exists.
WSLAVE robot already exists.
Fixed Point Motion in Cooperative mode is no supported.
No WSLAVE robot.
Out of sync.
Cannot continue non-cooperative instruction in cooperative mode.
No MASTER robot.
No SLAVE robot.
Servohand opened in clamp ON step.(CLAMP=XX)
Clamping position of servo Hand is error.(CLAMP=XX)
E8402
E8403
E8404
E8405
E8600
E8601
E8602
E8603
E8604
Cannot achieve set force of JtXX.
NC Joints lock signal not off.
Interpolation other than joint int. is unavailable.
It tries to move the Matehan axis with the axis locked.
（FSJ)Processing condition error.XX
Gap was over the lower pos. limit.
Reached the Penetration depth within min.processing time.
It could not reach the set Penetration depth within the appointed period.
Pressure cable disconnected.
A-36
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E8605
E8606
E8607
E8608
E8609
E8610
E8611
E8800
E8801
E8802
E8803
E8804
E8805
E8806
E8807
E8808
E8809
E8810
E8811
E8812
E8813
E8814
E8815
E8820
E8821
E8822
E8823
E8824
E8825
E8826
E8827
E8828
E8829
E8830
E8831
E8832
Error Message
Please input two set pressure or more.
Please input data in ascending order.
FSJ COUNTER ALARM.XX
(FSJ)FSJ schedule setting data is abnormal.
Setting tip force is over limit.
Setting rotation speed is over limit.
FSW Logging buffer is full.
Command value almost exceeds virtual safety fence.(SphereXX, LineXX)
Command value almost exceeds virtual safety fence.(SphereXX, ZUpper)
Command value almost exceeds virtual safety fence.(SphereXX, ZLower)
Command value almost invades restricted space.(SphereXX, Part.XX LineXX)
Command value almost invades restricted space.(SphereXX, Part.XX ZUpper)
Command value almost invades restricted space.(SphereXX, Part.XX ZLower)
Command value almost exceeds virtual safety fence.(ToolBox, LineXX)
Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
Command value almost invades restricted space.(ToolBox, Part.XX)
Command value almost exceeds virtual safety fence.(LinkXX, LineXX)
Command value almost exceeds virtual safety fence.(LinkXX, ZUpper)
Command value almost exceeds virtual safety fence.(LinkXX, ZLower)
Command value almost invades restricted space.(LinkXX, Part.XX LineXX)
Command value almost invades restricted space.(LinkXX, Part.XX ZUpper)
Command value almost invades restricted space.(LinkXX, Part.XX ZLower)
Current value exceeded virtual safety fence.(SphereXX, LineXX)
Current value exceeded virtual safety fence.(SphereXX, ZUpper)
Current value exceeded virtual safety fence.(SphereXX, ZLower)
Current value invaded restricted space.(SphereXX, Part.XX LineXX)
Current value invaded restricted space.(SphereXX, Part.XX ZUpper)
Current value invaded restricted space.(SphereXX, Part.XX ZLower)
Current value exceeded virtual safety fence.(ToolBox, LineXX)
Current value exceeded virtual safety fence.(ToolBox, ZUpper)
Current value exceeded virtual safety fence.(ToolBox, ZLower)
Current value invaded restricted space.(ToolBox, Part.XX)
Current value exceeded virtual safety fence.(LinkXX, LineXX)
Current value exceeded virtual safety fence.(LinkXX, ZUpper)
Current value exceeded virtual safety fence.(LinkXX, ZLower)
E8833
E8834
E8835
Current value invaded restricted space.(LinkXX, Part.XX LineXX)
Current value invaded restricted space.(LinkXX, Part.XX ZUpper)
Current value invaded restricted space.(LinkXX, Part.XX ZLower)
A-37
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
E8850
E8851
E8852
E8853
E8854
E8855
E8856
E8857
E8858
E8859
E8860
E8861
E8862
E8900
E8901
E8902
E9000
E9100
E9101
E9102
E9103
E9104
E9105
E9106
E9107
E9108
E9109
E9110
E9111
E9112
E9113
E9114
E9115
E9116
E9117
Appendix. Error Message List
Error Message
Disabled robot motion.
Detected area interference.
Detected arm interference.(XX, XX)
Failed to predict trajectory.
Detected near miss.(XX, XX)
No response from interference check board.
Communication error between interference check board and ARM CONTROL
board.
The number of robots is too many.
[INTERFERENCE CHECK BOARD]Processing time-out.
[INTERFERENCE CHECK BOARD]Can not receive data from ARM CTRL
BOARD.
[ARM CTRL BOARD]Cannot receive data from INTERFERENCE CHECK
BOARD.
Communication error between IL server and ARM CONTROL board.
Cable disconnected between IL server and ARM CONTROL board.
Detected torque for load presence is abnormal.
Detected torque for load absence is abnormal.
Stopped because motion limitation signal was input.
Joystick of JtXX is disconnected.
RSC)Watchdog timer overflow.
RSC)Overvoltage error. (3.3V)
RSC)Overvoltage error. (5V)
RSC)Internal processing time time-out.
RSC)RSC error occurred.(Code:54)
RSC)Robot number transmission, interprocessor communication error.
RSC)RSC operation status, interprocessor communication error.
RSC)I/O output, interprocessor communication error.
RSC)I/O check, interprocessor communication error.
RSC)Schedule management, timer synchronization error.
RSC)Main module, interprocessor communication error.
RSC)Operation part, interprocessor communication error.
RSC)Tool number input, interprocessor communication error.
RSC)I/O Port filtering, interprocessor communication error.
RSC)Robot diagnosis, interprocessor communication error.
RSC)RSC error occurred.(Code:5F)
RSC)Ethernet chip writing error.
RSC)Ethernet chip System. Open failure.
A-38
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E9118
E9119
E9120
E9121
E9122
E9123
E9124
E9125
E9126
E9127
E9128
E9129
E9130
E9131
E9132
E9133
E9134
E9135
E9136
E9137
E9138
E9139
E9140
E9141
E9142
E9143
E9144
E9145
E9146
E9147
E9148
E9149
E9150
Error Message
RSC)RSC error occurred.(Code:62)
RSC)RSC error occurred.(Code:63)
RSC)RSC error occurred.(Code:64)
RSC)Error log addition error.
RSC)Error log acquisition error.
RSC)Error log overwrite error.
RSC)RSC error occurred.(Code:68)
RSC)RSC error occurred.(Code:69)
RSC)Current time initialization error.
RSC)Current time acquisition error.
RSC)Current time set point error.
RSC)RSC error occurred.(Code:6D)
RSC)RSC error occurred.(Code:6E)
RSC)RSC error occurred.(Code:6F)
RSC)CPU error.
RSC)Memory error.
RSC)CPU status exchange failure.
RSC)Firmware CRC error.
RSC)RSC parameter CRC error.
RSC)RSC error occurred.(Code:75)
RSC)Mac address CRC error.
RSC)Initialization failure in "power down backup".
RSC)RSC error occurred.(Code:78)
RSC)RSC error occurred.(Code:79)
RSC)Power-source monitoring process error.
RSC)Pulse check error.
RSC)Readback error.
RSC)Relay contact check error.
RSC)Crosscheck error.
RSC)Input mismatching check error.
RSC)First-time encoder data receiving time-out.
RSC)FPGA operation error.
RSC)RSC error occurred.(Code:82)
E9151
E9152
E9153
RSC)RSC error occurred.(Code:83)
RSC)RSC error occurred.(Code:84)
RSC)RSC error occurred.(Code:85)
A-39
E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
E9154
E9155
E9156
E9157
E9158
E9159
E9160
E9161
E9162
E9163
E9164
E9165
E9166
E9167
E9168
E9169
E9170
E9171
E9172
E9173
E9174
E9175
E9176
E9177
E9178
E9179
E9180
E9181
E9182
E9183
E9184
E9185
E9186
Error Message
RSC)RSC error occurred.(Code:86)
RSC)Command value axes number error.
RSC)parameter error.(axes number / tool number)
RSC)"Command value input section" CRC error.
RSC)Robot number transmitting failure.
RSC)First command value receive time out.
RSC)USB communication impossible.
RSC)command value byte-number corruption.
RSC)USB Device recognition time-out.
RSC)command value receive time out.
RSC)RSC error occurred.(Code:90)
RSC)RSC error occurred.(Code:91)
RSC)RSC parameter read failure.
RSC)Robot number error.
RSC)Encoder data movement error.
RSC)Parameter and RC zeroing data mismatch.
RSC)TCP Communication Retry count over.
RSC)Rotary switch number error.
RSC)RSC error occurred.(Code:98)
RSC)RSC error occurred.(Code:99)
RSC)Parameter setting range over error.
RSC)Monitoring area parameter setting error.
RSC)Parameter error at TOOL monitoring invalid.
RSC)Operation part internal error.
RSC)RSC error occurred.(Code:9E)
RSC)RSC error occurred.(Code:9F)
RSC)Safety speed over.(TCP)
RSC)Speed over.(flange point)
RSC)Axis upper limit over.
RSC)Axis lower limit over.
RSC)Outside of a SSL area limit.(partial restricted area)
RSC)Outside of a SSL area limit.(restriction area)
RSC)Outside of a SSF area limit.
E9187
E9188
E9189
RSC)Positioning confirmation processing error.
RSC)TOOL verification error.
RSC)Distance error between flanges.
A-40
E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
E9190
E9191
E9192
E9193
E9194
E9195
E9196
E9197
E9198
E9199
E9200
E9201
E9202
E9203
E9204
E9205
E9206
E9207
E9208
E9209
E9210
E9211
E9300
E9301
E9302
D0001
D0002
D0003
D0004
D0005
D0006
D0007
D0008
D0009
D0900
D0901
Appendix. Error Message List
Error Message
RSC)RSC error occurred.(Code:EA)
RSC)RSC error occurred.(Code:EB)
RSC)RSC error occurred.(Code:EC)
RSC)RSC error occurred.(Code:EE)
RSC)RSC error occurred.(Code:EE)
RSC)RSC error occurred.(Code:EF)
RSC)RSC error occurred.(Code:F0)
RSC)RSC error occurred.(Code:F1)
RSC)RSC error occurred.(Code:F2)
RSC)RSC error occurred.(Code:F3)
RSC)RSC error occurred.(Code:F4)
RSC)RSC error occurred.(Code:F5)
RSC)RSC error occurred.(Code:F6)
RSC)RSC error occurred.(Code:F7)
RSC)RSC error occurred.(Code:F8)
RSC)RSC error occurred.(Code:F9)
RSC)Encoder receiving timeout error.
RSC)Encoder receiving timeout error 2.
RSC)Encoder status error.
RSC)Encoder data reading Retry count over.
RSC)RSC error occurred.(Code:FE)
RSC)RSC error occurred.(Code:FF)
Cannot rotate JtXX. Because disconnected axis.
Cannot rotate JtXX. Because invalid axis.
Rotation speed setting for JtXX is abnormal.
CPU error.(PC=XX)
Main CPU BUS error.(PC=XX)
VME BUS error.(PC=XX)
[ARM CONTROL BOARD]CPU error.(PC=XX)
[ARM CONTROL BOARD] CPU BUS error.(PC=XX)
[ARM CONTROL BOARD]Servo control software CPU error. (PC=XX,
CodeXX)
[Servo boardXX]CPU error. (CodeXX)
[Servo boardXX]Floating point exception. (CodeXX)
[Servo boardXX]CPU exception. (PC=XX)
Teach data is broken.
AS Flash memory sum check error.
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E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
D0902
D0903
D0904
D1000
D1001
D1002
D1003
D1004
D1005
D1006
D1007
D1008
D1009
D1010
D1011
D1012
D1013
D1014
D1015
D1016
D1017
D1018
D1019
D1020
D1021
D1022
D1023
D1024
D1025
D1026
D1027
D1028
D1029
D1030
D1031
Appendix. Error Message List
Error Message
Servo Flash memory sum check error.
IP board memory error. (XX)
Memory is locked due to AC_FAIL.
Read error of servo control software.
Download error of servo control software.
Init. error of servo software.
Init. error of servo control software.
[ARM CTRL BOARD]Watch dog error of Servo control software.
Servo board command error. (XX)
Servo system error.
Regenerative time over. [XX]
P-N low voltage. [XX]
P-N high voltage. [XX]
Regenerative resistor overheat. [XX]
As or servo software is not compatible with the robot model.
Servo type mismatch. Check the settings.
P-N capacitor is not discharged.
Servo system error.(Code=XX)
The servo data file does not exist.
Data applicable to the robot model not in servo data file.
Error of download of servo data.
Servo software version mismatch.
[ARM CONTROL BOARD]Watchdog error in timer built-in CPU for servo
control.
[ARM CONTROL BOARD]Synchronous error between CPUs.
Servo FPGA configuration data not found.
Configuration error in servo FPGA.(CodeXX)
Current mismatch betw. m-plexer&software. JtXX
[ARM CONTROL BOARD]Servo FPGA detected Watch dog error on ARMSC
Software.
[Servo boardXX]Detected Watch dog error.(Servo FPGA)
[Servo boardXX]Abnormal signal input from power sequence board.
[MCXX]Detected Watch dog error.
[Servo boardXX]DC power is abnormal.(Servo FPGA)
[Servo boardXX]AC primary power is abnormal.(Servo FPGA)
Cannot start communication with the servo boardXX.
Read error of servo software.
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Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
D1032
D1033
D1034
D1035
D1036
D1037
D1038
D1039
D1040
D1041
D1500
D1501
Error Message
[Servo boardXX]Download error of servo software.(CodeXX)
Connection Port No(XX) and Servo board No(XX) mismatch.
The servo data file is missing or not acceptable.(CodeXX)
[Servo boardXX]Init. error of servo software.(CodeXX)
[Servo boardXX]Download error of servo data.(CodeXX)
[Servo boardXX]Configuration error in servo FPGA.(CodeXX)
[Servo boardXX]Upload error of servo software initial data.(CodeXX)
[Servo boardXX]Download error of servo software initial data.(CodeXX)
[Servo boardXX]Device check error. (CodeXX)
JtXX axis brake release circuit is abnormal.
Encoder misread error. JtXX
Defective gun changer connection or encoder comm. error.
D1502
D1503
D1504
D1505
D1506
D1507
D1508
D1509
D1510
D1511
D1512
D1513
D1514
D1515
D1516
D1517
D1518
D1519
D1520
D1521
D1522
D1523
D1524
D1525
D1526
Amp overcurrent. JtXX
Current detector type (XX) mismatch!
Abn. curr feedback JtXX. (Amp fail, pwr harness disconnect)
Motor harness disconnected or amplifier overheated.(XX)
Power module error. JtXX
AC primary power OFF.
24VDC power source is too low.
Primary power source is too high.
Primary power source is too low.
+12VDC or -12VDC is abnormal.
Brake line error for JtXX.
Brake power is abnormal.(XX)
I/O 24V fuse is open.
Mismatch in setting of safety circuit as single/double.
Mismatch betw hard/software settings for HOLD backup time.
Blown fuse on safety circuit emergency line.
Mismatch in the Emer. Stop condition on safety circuit.
Mismatch in safety circuit LS conditions.
Mismatch in safety circuit TEACH/REPEAT condition.
Mismatch in safety circuit safety-fence condition.
Mismatch in cond. of safety circuit enabling device.
Mismatch in cond. of safety circuit ext.enabling device.
Incorrect operation of the safety relay.
Incorrect operation of MC(K1).
Incorrect operation of MC(K2).
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E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
D1527
D1528
D1529
D1530
D1531
D1532
D1533
D1534
D1535
D1536
D1537
D1538
D1539
D1540
D1541
D1542
D1543
D1544
D1545
D1546
D1547
D1548
D1549
D1550
D1551
D1552
D1553
D1554
D1555
D1556
D1557
D1558
D1559
D1560
D1561
D1562
Appendix. Error Message List
Error Message
Incorrect operation of MC(K3).
Controller temperature is out of range.
Signal harness disconnected or encoder power error.
Abnormal current limit of JtXX.
Heat sink on power block overheated.
(SSCNET)EnCoder communication error.(JtXX)(CodeXX)
(SSCNET)Absolute position of JtXX is erased.(CodeXX)
(SSCNET)Parameter error of JtXX.(CodeXX)
(SSCNET)Alarm of JtXX.(CodeXX)
JtXX does not move normally.
Brake rectifier relay failure.
DC 24V is abnormal.
Power supply circuit for PWM signal output malfunctioned.
Amplifier overheats.(XX)
Encoder type set in software and arm control board mismatch.
No Rotation data from multidrop encoder at initialize.
[Servo boardXX]DC 5V is abnormal.
[Servo boardXX]DC 3.3V is abnormal.
[Servo boardXX]DC 12V is abnormal.
[Servo boardXX]DC 2.5V is abnormal.
[Servo boardXX]DC 1.2V is abnormal.
[Servo boardXX]DC 1.0V is abnormal.
[Servo boardXX]Primary power source is too low.
[Servo boardXX]Primary power source is too high.
[Servo boardXX]AC primary power OFF.
[MCXX]DC 3.3V is abnormal.
[MCXX]DC 5V is abnormal.
Brake power in servo amplifiers abnormal.
Amplifier temperature is out of range or regenerative resistor overheats.
Control power in servo amplifier is abnormal.
[Power sequence board]DC 3.3V is abnormal.
[Power sequence board]DC 5V is abnormal.
[Power sequence board]DC 12V is abnormal.
[Power sequence board]DC 24V is abnormal.
[Power sequence board]AC primary power OFF.
[Power sequence board]AC primary power voltage is too high.
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Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
D1563
D1564
D1565
D1566
D1567
D1568
D1569
D2000
D2001
D2002
D2003
D2004
Error Message
[Power sequence board]AC primary power voltage is too low.
[Power sequence board]Remote power off signal was detected.
Cannot access power sequence board.(CodeXX)
P-N capacitor has not discharged.(Servo boardXX)(MCXX)
[Servo boardXX]Primary Power source is error.
[Servo boardXX]Power supply circuit for PWM signal output malfunctioned.
Servo amplifier is abnormal.(XX)
No response from Comm. board for Laser sensor.
RI/O or C-NET board initialize error.
No response from the Arm ID board.
No data in the Arm ID board.
Mismatch data in the Arm ID board.
D2005
D2006
D2007
D2008
D2009
D2010
D2011
D2012
D2013
D2014
D2016
D2017
D2018
D2019
D2020
D2021
CC-LINK software version mismatch.
Watch dog error on communication board for Explosion proof TP.
No response from the built-in sequence board.
Magnet is Contactor of groupXX is stuck.
Sensor for detecting pressure in enclosure is abnormal.
Sync. error between User I/F and Arm control board.
Parameter download error betw User I/F & Arm control boards.
Soft Absorber error. Turn OFF & ON the control power.
Change gain error. Turn OFF & ON the control power.
Robot network initialize error.
No response from the Arm control board.
No response from User I/F board.
[ARM CTRL BOARD]No response.
[ARM CTRL BOARD]Servo software no response.
[ARM CTRL BOARD]Servo control software no response.
Arm data file is not found.
D2022
D2023
D2024
D2025
D2026
D2027
D2028
D2029
Arm data is not found.
Failed to load arm data.
[ARM CTRL BOARD]Robot type setting failed.
Robot codes set in software and Arm ctrl board do not match.
Codes set in software & curr. sensor I/F b'd do not match.
Codes set in software and power block do not match.
(SSCNET) Initialization error. (CodeXX)
Motor codes in software & Arm control b'd mismatch.(Jt-A)
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E Series Controller
Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
D2030
D2031
D2032
D2033
D2034
D2035
D2036
D2037
D2038
D2039
D2040
D2041
D2042
D2043
D2044
D2045
D2046
D2047
D2048
D2049
D2050
D2051
D2052
D2053
D2054
D2055
D2056
D2057
Error Message
Codes set in software & curr. sensor I/F b'd mismatch.(Jt-A)
Codes set in software and on add'l pwr block mismatch.(Jt-A)
Motor codes set in software and Arm ctrl b'd mismatch.(Jt-B)
Codes set in software & curr. sensor I/F b'd mismatch.(Jt-B)
Codes set in software and on add'l pwr block mismatch.(Jt-B)
Program execution error.
(SSCNET)System error occurred in 1LP I/F board. (CodeXX)
Safety unit circuit is abnormal.
(SSCNET)Interface board is not installed.
(SSCNET)Communication error of JtXX on initialization.
(SSCNET)Initialization error of JtXX.(CodeXX)
Connection of the signal harness is wrong.
Servo amp and robot arm are mismatched.
Arm I/F board detects AC-Fail.
[ARM CONTROL BOARD]No response from Servo FPGA software.
[ARM CONTROL BOARD]Device check error. (CodeXX)
Relay error on purge control board. (relay XX)
Jumper setting error or Safety relay failure on Servo CPU board.
DC 12V Voltage source error on purge control board.
Over current error in interlock relay drive circuit(1) for purge control board.
Over current error in interlock relay drive circuit(2) for purge control board.
Communication error on purge control board.
Hardware setting for the external axis amplifier has discrepancy. robot=n
(FANXX-XX)Rotational speed of fan is abnormal.(Servo boardXX)
Codes set in software and power block do not match.(Code:XX)
[Power sequence board]Watchdog error was detected.
[I/O board(No.XX)]Several boards have same ID address.
[Servo boardXX]No response from Servo FPGA device.
D2058
D2059
D2060
D2061
D2062
D2063
D2064
D2065
D2066
[Main CPU board]DC power supply is abnormal.(XX mV)
1SP board is abnormal.(DXX)
Safety unit is abnormal.(DXX)
Mother board is abnormal.(DXX)
1QL board is abnormal.(DXX)
MC unit is abnormal.(DXX)
[Purge control board]Pressure within enclosure is low.(during purging)
Safety relay is abnormal which cut off brake power when inner pressure is low.
[Purge control board]DC is abnormal.(12V)
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Kawasaki Robot Troubleshooting Manual
Appendix. Error Message List
Code
D2067
D2068
D2069
D3800
D3801
D3802
D3803
D3804
D3805
D3806
D3807
D3808
Error Message
[Main CPU board]Communication with purge control board is abnormal.
[IO board No. XX]Device check failure.(CodeXX)
[ANYBUS interface board(No.XX)]Several boards have the same ID address.
Communication board memory error. (XX)
JtXX axis amp interface error 1.
JtXX axis amp interface error 2.
JtXX axis amp interface error 3.
JtXX axis amp power element error.
JtXX axis amp current detector error.
JtXX axis amp main circuit voltage unmatch.
JtXX axis amp memory error.(EEPROM error)
JtXX axis amp inside RAM error.
D3809
D3810
D3811
D3812
D3813
D3814
D3815
D3816
D3817
D3818
D3819
D3820
D3821
D3822
D3823
D3824
D3825
D3826
D3828
D3829
D3830
D3831
D3832
D3833
D3834
JtXX axis amp servo processor error.
JtXX axis amp parameter error.
JtXX axis amp initial processing error.
JtXX axis amp undefinition error 1.
Amp communication I/F board initialed check error.(XX)
Amp communication I/F board undefinition error.(XX)
It is not possible to communicate with JtXX axis amp.
JtXX axis amp communication frame reception error.
JtXX axis amp communication frame reception timeout.
JtXX axis amp communication bank data error.
JtXX axis amp init timeout.
JtXX axis amp communication undefinition error.
Motor harness connection point is error.
Motor parameter is not consistent with controller. JtXX
FAN NO. XX in Controller is out of order.
Fuse NO.XX on IO board NO.1 is open.
Fuse NO.XX on IO board NO.2 is open.
Robot DC voltage error.
Controller type error.
K1 and/or K2 works wrong.
PN high voltage error.
PN low voltage error.
Register over time error.
Discharge resistor overheated.
Power board switching circuit is abnormal.
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E Series Controller
Kawasaki Robot Troubleshooting Manual
Code
D3835
D3836
D3837
D3838
D3839
D3840
D3841
D3842
D3843
D4000
D4001
D4500
D4501
D4502
D4503
D4504
D6000
D6001
Appendix. Error Message List
Error Message
Power board inrush current limiting circuit is abnormal.
DC Power voltage is abnormal.(CodeXX)
JtXX axis amp control power supply error.
Power board is abnormal.
Servo control line error.
FAN NO. XX on power board is out of order.
RobotXX servo amp is missing.
Control power supply for a power device is abnormal.
Brake release setting is abnormal.
[DIAG]Error is detected in RS232C.(Code:XX)
[DIAG]Error is detected in Ethernet.(Code:XX)
Fieldbus interface board is not detected.
ABMA-PDP)I/F module error. XX
FIELD-BUS-INIT)Error reply. XX
FIELD-BUS-INIT)Reply timeout. XX
ANYBUS)OUT/FB.CTRL request timeout. XX
Over temperature error in Barrier unit.
Mutual-Wait initialize error.
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Kawasaki Robot Controller E Series
TROUBLESHOOTING MANUAL
February 27 : 1st Edition
Published by KAWASAKI HEAVY INDUSTRIES, LTD.
90206-1045DEA
Copyright © 2009 KAWASAKI HEAVY INDUSTRIES, LTD.
All rights reserved.