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Help needed to troubleshoot a KE2060 machine (location Ireland)

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#85495

Help needed to troubleshoot a KE2060 machine (location Ireland) | 20 August, 2020

Hi Guys,

I 'm having trouble with a JUKI KE2060 - multiple errors on Z, X, Y axis (it seems that the problem moves around) - the error codes are E602137 E603112 any help or an electrical diagram of the machine are highly appreciated A

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#85502

Help needed to troubleshoot a KE2060 machine (location Ireland) | 21 August, 2020

Here's a link to all the docs I have on the 2060, hope it's helpful.

https://drive.google.com/file/d/1cYAZvwXgELdX25IUM5l8SzA0MaV6oufI/view?usp=sharing

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#85507

Help needed to troubleshoot a KE2060 machine (location Ireland) | 24 August, 2020

Much appreciated, really helpful Thanks, Aurash

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#85508

Help needed to troubleshoot a KE2060 machine (location Ireland) | 24 August, 2020

I'm stuck with this - if anyone knows a good technician with KE2060 expertise - please let us know.

So far we checked the power going to the Z-drives, XY- drives all seems ok - no error leds on the Motor Drives (all amber)

When trying to go in Origin - we get a Z1 error or X error, or a Y error. Sometimes the Y (or X) axis makes a jump (short and violent) before throwing the error - this jump doesn't seem right and it happens with the front cover open.

Aurash

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#85509

Help needed to troubleshoot a KE2060 machine (location Ireland) | 24 August, 2020

Aurash, we own Yamaha machinery but just throwing it out there...are the movements of the motors smooth or with friction? Is it possible that the linear screw rods (as in our machinery) require to be lubricated? There are special lubricants for each such machine and will be documented by the vendor.

We have sourced many such parts from a repeat supplier to us in Shenzhen. Also know that Juki is very popular in Asia and used often by Foxconn. Consider to ping the same supplier to ask for assistance. They sell the Juki machines so should have advice on the issue.

Contact: Elissa smtwenzhan@163.com At the very least, they will have spare Juki parts. So far the quality has been great at fair costs. About to order transport belts for our Yamaha machine.

Hope this helps.

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#85538

Help needed to troubleshoot a KE2060 machine (location Ireland) | 27 August, 2020

Is Juki support not helping you out with this? We get tremendous support from Juki support here in the US on troubleshooting.

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#85539

Help needed to troubleshoot a KE2060 machine (location Ireland) | 27 August, 2020

I opened a case on the JUKI support in Germany and I got some help but we are in the same spot like a week ago. I have 30 years of industrial automation expertise I checked everything I've been told to check - searching trough detailed logs and send them, even made a video with the behavior. I don't think JUKI has other machines in Ireland (I'm Paddy the last with my 4 machines) so I'm not very high in their list of priorities.

Aurash

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#85546

Help needed to troubleshoot a KE2060 machine (location Ireland) | 28 August, 2020

From what you explain: 1. check all movements X,Y and Z are moving free while machine is off. 2. Resit all driver cards. 3. Check interface cables or boards. Not sure if Juki is using CAN or other interface standard, but random motor errors might be coming from a interface connection being lose or broken. Measure and check all these connections.

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#85554

Help needed to troubleshoot a KE2060 machine (location Ireland) | 31 August, 2020

After reading the machine logs it seems that the problem is on the X-axis but the safety mechanism is disabling all the Servos and the Axis system (all axes) are in error state (that's why the error messages are showing on different axes)

The JUKI machines have a shared bus called SyncNet for talking to the servo drivers and the axis counters - that bus is working because I can run a utility in the software (AxisMonitor and I can see the coordinates changing is a push the X,Y,Z,Theta by hand)

One thing which is massively stupid is when an error from the axis is raised the servo power is cut and all the errors displayed on the servo drivers LEDs are disappearing. Basically you don't have the chance to see the errors because the safety mechanism kicks in.

I suspect a Servo driver problem because when the X-axis suposed to move in origin (towards the home sensor) it makes a jump movement sometimes in the right direction and sometimes in the wrong direction (which is suggesting a driver problem) - it's a pity I can't see the error on the LEDS.

Aurash

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#85567

Help needed to troubleshoot a KE2060 machine (location Ireland) | 31 August, 2020

your troubleshooting makes sense to me. If the drives are replacable, replace X and Y drivers and see if the error moves with the driver.

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#85568

Help needed to troubleshoot a KE2060 machine (location Ireland) | 31 August, 2020

I wish it was so simple :-) In their wisdom the machine designers choice was to have servo drivers with two channels (one channel less powerful and one channel more powerful) - so each card is driving a X motor and a Y motor.(the X axis is made of 2x 600W motors and the Y axis is made 2x 1600W motors) Swapping them is not helping. But I see your point - and I thank you for the suggestion. Aurelian

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#85593

Help needed to troubleshoot a KE2060 machine (location Ireland) | 3 September, 2020

Check the backup battery. My KE2020 experienced the same symptoms and its was caused by bad backup battery. I unplugs the power source from the battery and plugs direct to the AC outlet and the machine working fine. Ordered 2 replacement batteries online and replaced them.

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#85604

Help needed to troubleshoot a KE2060 machine (location Ireland) | 7 September, 2020

Thanks for the good advice - the UPS is fine (to be sure I disable it but the problem was still there)

In the meantime we found the root cause - the XMP SyncNet card failed. We replaced it and it's all back in motion.

Many thanks to all who had replied I'll do my best to return the favor when someone else has a problem. Stay safe, Aurash

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