Kuka KR C2 User manual

CONTROL CABINET

KR C2 -- USA

edition2005

User Manual

Fault Analysis / Diagnosis

Issued: 20 Dec 2004

BetrHbKRC2FL--USA--Fehler 11.04.00 en

Version: 00

1 of 86

e

Copyright 2004

KUKA Roboter GmbH

Zugspitzstrasse 140

D--86165 Augsburg

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.

Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in the case of a replacement or service work.

We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in subsequent editions.

Subject to technical alterations without an effect on the function.

2 of 86 BetrHbKRC2FL--USA--Fehler 11.04.00 en

Contents

1

1.1

1.2

1.3

2

2.1

2.2

2.3

3

3.2

3.2.1

3.2.2

3.2.3

3.3

3.3.1

3.3.2

3.3.3

3.3.4

3.3.5

3.3.6

3.3.7

3.1

3.1.1

3.1.2

3.1.3

3.1.4

3.1.5

3.4

3.4.1

3.4.2

3.4.3

3.4.4

3.4.5

3.5

3.5.1

3.5.2

3.5.3

3.5.4

3.5.5

3.6

3.6.1

3.6.2

Repair and procurement of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair by KUKA service personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procurement of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault analysis and elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Isolation of faults using checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Isolation of faults by exchanging components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical fault profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault profiles related to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC--related peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault profile checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault profiles related to DSE and machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program crashes (with possible loss of mastering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The robot does not move in jog mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The drives cannot be switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DSE error messages when booting the system

DSE x not found

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

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

Memory test error DSE x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DSE x does not run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DSE axis assignment Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power module axis Ax not / incorrectly connected

Machine data loader canceled

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

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

Incorrect machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DSE error messages during operation

Watchdog interpolation cycle Ax

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

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

Synchronization error with DSE Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulator limit exceeded Ax

Stopped Ax

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

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

Motor temperature Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault profiles related to the MFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller hangs when loading software components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KCP control panel does not work

No image on KCP

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

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

Operating mode switchover on KCP does not react . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When PC is booted, the operating system VxWorks does not run up . . . . . . . . . . . . . . . . . .

Fault profiles related to the KCP

No display on the LCD

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

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

Drives cannot be switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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9

17

17

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17

18

18

18

18

15

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9

9

9

9

9

10

19

19

19

19

19

19

20

20

20

20

21

21

22

22

22

8

8

8

8

7

7

7

7

User Manual

4

4.1

4.2

3.6.3

3.6.4

3.6.5

3.7

3.7.1

3.7.2

3.7.3

3.7.4

3.7.5

5

5.1

5.1.1

5.1.2

5.1.3

5.1.4

6

No entries can be made via KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMERGENCY STOP cannot be acknowledged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Space Mouse does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault profiles related to a field bus card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Communication via diagnostic interface not possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Error message “xxxxx I/O driver configuration error” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After inserting the field bus card: no display, controller does not boot (Stop 0) . . . . . . . . . .

The controller “hangs” after initialization of the field bus card . . . . . . . . . . . . . . . . . . . . . . . . .

No external power supply for slave when controller switched off . . . . . . . . . . . . . . . . . . . . . .

Servo drive module messages and error displays

Servo drive module LEDs (KSD1)

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

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

KCP messages for drives diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KPS--600 messages and error displays . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KPS--600/10 and /20 LED indicators

Meaning of LEDs 1 and 2

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

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

Meaning of LEDs 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Meaning of LEDs 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KPS--600 error messages on the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KPS--27 operating state indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

8

DSE--IBS operating state indicators

RDC2 operating state indicators

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

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

9

9.1

9.2

ESC diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Softkey bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESC diagnosis error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 DSE--RDW diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1

Main menu of the DSE--RDW diagnostic tool

10.1.1

Language selection

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

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

10.1.2

System info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.3

MFC2 register display

10.1.4

DSE IBS information

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

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

10.1.5

Display RDC table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.6

RDC offset and symmetry adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.7

Check RDC--DSE communication

10.1.8

Drive bus diagnostics

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

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

10.1.9

Drive bus error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.10 Drive bus diagnostics -- KPS--2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.11 Drive bus KSD 1--16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.12 Error messages valid for the KPS--600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.13 Error messages valid for the KSDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Oscilloscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.1

File selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


32

33

39

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

53

54

34

35

37

22

23

23

24

24

24

24

24

24

25

25

26

27

27

28

28

28

29

31

11.1.2

Oscilloscope screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.3

The information window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.4

The softkey bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.5

The color softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.6

The scaling function

11.1.7

The zoom function

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

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

11.1.8

The Save function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.9

The r.m.s. value function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.10 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.11 The cursor functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.12 The filter function

11.1.13 Superposing traces

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

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

11.1.14 Changing color assignments

11.1.15 Switching curves on and off

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

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

11.2

Configure

11.2.1

General

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

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

11.2.2

Trigger condition

11.2.3

Trace status

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

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

11.2.4

Trace data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2.5

Examples of a trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Robot repair card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

64

66

67

58

58

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60

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55

56

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71

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User Manual


1

1 Repair and procurement of spare parts

Repair and procurement of spare parts

Repairs to the KR C may only be carried out by KUKA customer support personnel or by customers authorized to do so after participation in a relevant KUKA Robot Group service seminar.

1.1

Customer repair

As far as customer repairs to the KR C are concerned, only the exchange of modules is envisaged. A defective motherboard is exchanged together with the PC rack.

1.2

Repair by KUKA service personnel

Repairs within modules may only be carried out by specially trained KUKA Robot Group personnel.

A repair by KUKA Robot Group service personnel carries the following guarantees:

G carried out by specially trained, experienced personnel

G compliance with the ESD directives

G use of the required special tools

G optimal conditions for locating faults and searching for the exact causes

G technical revisions carried out

G overall test of the PC on completion of repair.

1.3

Procurement of spare parts

The article numbers for spare parts are listed in the electronic spare parts catalog (KUKA

Parts) on a CD--ROM that accompanies every control cabinet.

The KUKA Robot Group supplies the following types of spare parts for KR C repairs:

G

New parts

Once the new part has been installed, the part that has been removed can be disposed of.

G

Exchange parts

Once the exchange part has been installed, the part that has been removed is returned to the KUKA Robot Group.

A “Robot Repair Card” is supplied with the exchange parts.

The Repair Card must be completed (see Chapter 12) and returned to the KUKA Robot

Group.


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2

User Manual

Fault analysis and elimination

The following procedure is recommended for isolating the cause of the fault and enabling effective repair of the KRC:

2.1

Fault analysis

Is the fault reproducible?

-- Permanent fault

-- Sporadic fault

Did the fault occur after installation or conversion?

-- Transportation damage

-- Commissioning faults

Did the fault occur during operation?

-- Operator influence, incorrect operation

-- Program modifications

-- Software configuration modifications

Was the fault caused by external factors?

-- Electrical factors such as undervoltage/overvoltage, static electricity, interference fields

-- Mechanical factors such as impact, vibration

-- Environmental factors such as heat, cold, humidity

What is the fault profile?

-- Observe the status of operator control and display elements on the KR C

(switch positions, lamps, LEDs)

-- Interpret error messages in the message window of the KCP

(for more detailed information see Section 3.2 and the following sections)

-- Collate the statuses and error messages of higher--level controllers

(process control systems, automation components)

-- Read logbook entries

2.2

Isolation of faults using checklists

The cause of the fault can be isolated by comparing the fault profile with a list of typical fault profiles (see Section 3.1.5).

2.3

Isolation of faults by exchanging components

In the case of a potentially defective overall system, functioning modules are introduced into the system one after the other and changes in the behavior of the system are observed.

In the case of a potentially defective component, this is introduced into a functioning system and changes in the behavior of the system are observed.


3 Typical fault profiles

3 Typical fault profiles

3.1

Fault profiles related to the PC

3.1.1

Power supply

The motherboard and drives are supplied with power by an integrated switched--mode power supply.

Typical power supply fault profiles are:

-- Supply voltage that is characterized by dropouts or spikes

-- Output voltage overload

-- Output voltage failure

-- Internal overheating due to fan failure

-- Defects in power switch and ATX power--on logic

3.1.2

Basic configuration

The processor, main memory, CMOS memory and other hardware are integrated onto the motherboard.

Typical faults in the motherboard basic configuration are:

-- Memory faults in the CMOS--RAM due to undervoltage in the lithium battery

-- Incorrect BIOS entries

-- Memory faults in the main memory (RAM modules)

-- Overheating due to failure of CPU fan

3.1.3

Drives

The hard drive, floppy disk drive and CD--ROM drive are integrated into the PC chassis.

Typical faults in the drives are:

-- Hard drive defect caused by impact or vibration

-- Data error caused by dust in the floppy disk drive and CD--ROM drive

-- Cabling fault in the IDE bus and floppy disk bus

3.1.4

PC--related peripherals

PC--related peripherals include input and output devices and additional plug--in cards.

Typical faults in the PC--related peripherals are:

-- Keyboard does not respond

-- Monitor display faults

-- Fault in the interplay between the VGA chip and the KVGA card

-- Bus errors and communication errors due to incorrectly configured plug--in cards

(MFC, Ethernet, field bus cards)


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3.1.5

Fault profile checklist

Main switch on PC to “ON”, system fails to boot, display stays dark, power supply fan and CPU fan do not work

Possible causes:

-- Power supply defective

-- Short circuit on the motherboard

-- Short circuit on a connected device

Elimination of fault:

-- Disconnect all devices from the power supply unit. Switch on PC and measure output voltages at the power supply unit. If an output voltage is too low, exchange the power supply unit.

-- Connect the power supply to the motherboard with the power supply unit switched off.

Switch on PC and measure supply voltages at the power supply unit. If an output voltage is too low, exchange the PC rack (motherboard fault).

-- Reconnect each device in turn to the power supply unit (drives, plug--in cards) with the power unit switched off. Switch on PC and measure output voltages at the power supply unit. If an output voltage is too low, exchange the device in question.

System does not boot, display stays dark

Possible causes:

-- Ribbon cable not correctly connected (male connector without coding)

-- Defective expansion card (Interbus, MFC, KVGA)

-- Memory modules (RAM modules) not correctly snapped into place (contact fault)

-- Memory modules defective

-- Defective motherboard


-- Connect ribbon cable correctly (red marking on the ribbon cable corresponds to pin 1)

-- Disconnect expansion cards (Interbus, Ethernet card) and test system again; replace expansion cards if necessary

-- Snap memory modules correctly into place

-- Exchange memory modules

-- Exchange PC rack

System boots sporadically, display stays dark

Possible causes:

-- Incorrect BIOS version


-- Carry out BIOS update



3 Typical fault profiles (continued)

System boots normally, display stays dark

Possible causes:

-- KVGA defective

-- KCP2 connecting cable snapped

-- 24 V supply voltage for KCP2 not present in MFC3


-- Exchange KVGA

-- Exchange KCP2 connecting cable (KVGA to X19)

-- Exchange connecting cable (X3) from the ESC--CI board to the MFC (X807)

-- Exchange safety logic

System crash when booting, no keyboard entries possible

Possible causes:



-- Exchange PC rack

The system repeatedly resets itself

Possible causes:

-- Memory modules defective

-- Memory modules of different types installed

-- Defective or incorrectly installed graphics card (KVGA)


-- Exchange defective memory modules

-- Install memory modules that are all of the same type

-- Check KVGA card for correct fit in PCI slot, exchange if necessary

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BIOS error message “CMOS Checksum Error”

Possible causes:

-- Undervoltage in lithium battery on the motherboard

-- Incorrect or missing entries in CMOS setup

-- CMOS memory on motherboard defective


-- Replace lithium battery

-- Check entries in CMOS setup and correct if necessary

-- Exchange PC rack

BIOS error message “MEMORY TEST FAILED”

Possible causes:

-- Defective memory module(s)


-- Exchange memory module(s)

Cannot boot from hard disk

Possible causes:

-- BIOS fails to detect hard drive

-- IDE cable incorrectly connected

-- IDE drives incorrectly configured

-- Power supply connector incorrectly connected

-- Hard drive defective

-- IDE interface on motherboard defective


-- Activate “Autodetect” in CMOS SETUP. Set boot sequence.

-- Compare hard drive parameters in CMOS setup with specifications on label of hard drive.

-- Check IDE cable (lateral offset, PIN1 marking)

-- Check drive configuration (master/slave, slave present, CHS/LBA)

-- Ensure that power supply connector is correctly connected

-- Exchange hard drive

-- Exchange PC rack (motherboard fault)




Cannot access floppy disk drive (FDD)

Possible causes:

-- CMOS setup: FDD type not correctly entered or FDD controller deactivated

-- FDD data cable and power supply not connected correctly

-- FDD defective

-- FDD interface on motherboard defective


-- Check CMOS settings and correct if necessary

-- Connect data cable and power supply correctly

-- Exchange FDD

-- Exchange PC rack

CD--ROM drawer does not open

Possible causes:

-- Power supply not correctly connected

-- CD--ROM drive defective


-- Connect power supply correctly

-- Exchange CD--ROM drive

CD--ROM drawer opens, CD--ROM cannot be read

Possible causes:

-- BIOS fails to detect CD--ROM drive

-- IDE cable incorrectly connected

-- IDE drives incorrectly configured

-- Power supply connector incorrectly connected

-- CD--ROM drive faulty

-- CD--ROM defective or inserted incorrectly


-- Check CMOS entry for CD--ROM drive

-- Connect IDE cable correctly

-- Configure IDE drives (master/slave, slave present, CHS/LBA)

-- Exchange CD--ROM drive

-- Exchange CD--ROM or insert it correctly (label upwards!)

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Operating system crashes with exceptional error (blue screen)

Possible causes:




Controller hangs when loading software components

Possible causes:

-- MFC not correctly connected

-- MFC defective

-- Additional expansion card (e.g. Interbus) interfering with functioning of MFC

-- PCI bus on motherboard faulty


-- Connect MFC correctly

-- Exchange MFC

-- Remove expansion card and run controller up again

-- Exchange PC rack

KUKA HMI does not boot and is aborted with a General Protection fault

Possible causes:

-- Defective files in the software installation

-- Settings in CMOS setup incorrect



-- Reinstall control software

-- Check settings in CMOS setup




3.2

Fault profiles related to DSE and machine data

3.2.1

Program crashes (with possible loss of mastering)

Faulty cable shields can seriously reduce the controller’s immunity against interference. In the event of error messages affecting DSE--IBS, yet for which no other cause is apparent, the connecting cable between the resolver interface and the control cabinet should be checked.

3.2.2

The robot does not move in jog mode

The robot does not move in jog mode; the brakes and servo enable remain closed. The axis-specific actual values do change, however.

The following points must be checked:

-- Is the variable value Office=FALSE entered in the file hw_inf.ini?

(Path: C:\KRC\Roboter\init\hw_inf.ini)

-- Are the correct servo files loaded?

-- Are the correct machine data configured?

If no machine data have been copied into the directory, the standard machine data in the system for the Office version are used, i.e. the axes are all in axis simulation mode.

To check the machine data, carry out the following steps:

-- By pressing the menu key “Configure” and selecting the menu item “Settings” →

“Robot name”, you can see which machine data are present and whether or not they are valid.

-- By pressing the menu key “Monitor” and selecting the menu item “Modify variable”, you can check whether or not the correct machine data have been loaded into the system. $TRAFONAME[ ] (transformation name) must contain the name of the robot and $AX_SIM_ON (axis simulation) must be zero. If $TRAFONAME[ ] is “OFFICE

ROBOT KR125”, then the machine data are completely missing in the Mada directory.

-- If the machine data are incorrect, copy the correct machine data from the CD into the directory C:\KRC\Roboter\KRC\mada.

With KUKA HMI active, the machine data are overwritten again during the Power Off backup.

-- Exit the HMI beforehand, by means of EXIT, or

-- Carry out a controlled exit from the boot sequence and change the machine data


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3.2.3

The drives cannot be switched on

-- Is the peripheral connector X11 plugged in?

If the connector is not connected or is incorrectly wired, the message “EMERGENCY

STOP” or “Motion enable” or “Operator safety” is displayed.

-- Has the DSE booted?

If the DSE has booted, the LED on the DSE flashes.

-- Check the E--Stop circuits using the ESC diagnostic tool.

-- Is the VxWorks real--time operating system still running?

-- Is there an encoder error present at any axis?

If there is an encoder error, the controller cancels the RC Ready signal on the MFC and the brakes are applied.

-- Is there a KSD (KUKA Servo Drive) error message present? Certain errors

(e.g. overcurrent, overvoltage) cause the servo drive module to deactivate the drives automatically.



3.3

DSE error messages when booting the system

3.3.1

DSE x not found

The MFC checks whether a DSE is connected. If no connected DSE is detected, the error message “DSE x not found” is generated. The loading of the machine data is canceled.

The following follow--up message is generated: “DSE axis assignment Ax, machine data loader canceled, erroneous %1 machine data”.

Possible causes:

-- DSE not connected

-- DSE incorrectly configured

-- DSE defective

-- MFC defective

3.3.2

Memory test error DSE x

If a connected DSE is detected, a memory test of the dual--port RAM is initiated. If this memory is faulty, the error message “Memory test error DSE x” is generated. The loading of the machine data is canceled.


Possible causes:

-- DSE dual--port RAM defective

-- Access via the PCI bus to the DSE memory disrupted by another plug--in card.

3.3.3

DSE x does not run up

The servo--control program for the DSE is loaded from the hard drive into the DSE memory and started when the PC is booted.

If the DSE does not boot when the program is loaded, the error message “DSE x does not run up” is generated. The loading of the machine data is canceled.


Possible causes:

-- DSE incorrectly configured (jumper)

-- DSE defective


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3.3.4

DSE axis assignment Ax

Either the error is merely a follow--up message or the axis assignment with $DSECHANNEL is incorrect.

Possible causes:

-- DSE, MFC defective (follow--up message)

-- $DSECHANNEL incorrect axis assignment

3.3.5

Power module axis Ax not / incorrectly connected

The current calibration of the axes is compared with the value $CURR_CAL in the machine data list. The message is generated if the axis connector to the power module is incorrectly connected.

Further possible causes:

-- MFC/DSE, KPS or KSD function faulty

-- Ribbon cable between DSE and power module incorrectly connected or defective


3.3.6

Machine data loader canceled

Possible causes:

-- The error is a follow--up message relating to a previous error

-- Other machine data in the machine data list are incorrect

3.3.7

Incorrect machine data

Possible causes:

-- The error is a follow--up message relating to a previous error

-- Other machine data in the machine data list are incorrect



3.4

DSE error messages during operation

3.4.1

Watchdog interpolation cycle Ax

The interpolator sends one feed value per interpolation cycle to the DSE. If this transmission is interrupted for one or more cycles, the watchdog is triggered and this error message is generated.

3.4.2

Synchronization error with DSE Ax

The interpolator sends one feed value per interpolation cycle to the DSE. If the DSE does not read this feed value from the interface, the synchronization monitoring is triggered and this error message is generated.

3.4.3

Regulator limit exceeded Ax

The position controller output has gone into limitation, i.e. the axis does not follow the command value. Possible causes:

G

The motor is blocked because

-- the brake does not release

-- the robot has caused a collision during a motion

-- the axis has hit an end stop

G

The acceleration is too high because

-- incorrect machine data have been loaded

-- an incorrect weight is entered in the variable $LOAD

-- the weight on the tool is too high

G

There is no servo--control of the motor because

-- the enable signal is missing (KSD defective)

-- the motor cables have been interchanged or are defective

-- the motor is not connected

G

The controller amplification is incorrect

3.4.4

Stopped Ax

The axis has moved outside the standstill window, although the interpolator had not specified a movement. Possible causes:

G

The brake is defective and the axis sags.

G

The weight on the tool is greater than the holding torque of the axis.

G

There is no servo--control of the motor because

-- the enable signal is missing (KSD defective)

-- the motor cables have been interchanged or are defective

-- the motor is not connected

3.4.5

Motor temperature Ax

The permissible motor temperature has been exceeded. Possible causes:

-- External temperature is too high

-- Encoder cable is interrupted

-- The motion pauses in the motion program are too short

-- The axis is sluggish

-- The weight on the flange is too high


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3.5

Fault profiles related to the MFC

3.5.1

Controller hangs when loading software components

Possible causes:

-- MFC cannot be initialized

-- MFC incorrectly connected

-- Additional expansion card (e.g. Interbus) interfering with functioning of MFC



-- Remove expansion card and run controller up again

-- Check for correct fit of MFC

-- Exchange MFC

-- Exchange motherboard

3.5.2

KCP control panel does not work

Possible causes:

-- CAN controller on the MFC faulty, connecting cable defective

-- KCP, cable or connector faulty


-- Exchange MFC

-- Exchange KCP

3.5.3

No image on KCP

Possible causes:

-- Power supply to connector X5 for KCP missing

-- KCP, cable or connector faulty

-- KVGA card defective



-- Restore power supply

-- Exchange KCP

-- Exchange KVGA card

-- Exchange MFC



3.5.4

Operating mode switchover on KCP does not react

Possible causes:

-- Mode detection on MFC defective

-- Mode selector switch on KCP, cable or connector faulty


-- Exchange MFC

-- Exchange KCP

-- Exchange ESC board

3.5.5

When PC is booted, the operating system VxWorks does not run up

Possible causes:

-- MFC defective


-- Exchange MFC


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3.6

Fault profiles related to the KCP

3.6.1

No display on the LCD

Possible causes:

-- Connecting cable defective

-- KVGA defective

-- KCP defective


-- Exchange connecting cable

-- Exchange KVGA

-- Exchange KCP

3.6.2

Drives cannot be switched on

Possible causes:


-- Enabling switch jammed

-- KCP defective

-- ESC board defective



-- Exchange KCP

-- Exchange MFC

-- Exchange ESC board

3.6.3

No entries can be made via KCP

Possible causes:


-- MFC defective (CAN bus)

-- KCP defective



-- Exchange MFC

-- Exchange KCP



3.6.4

EMERGENCY STOP cannot be acknowledged

Possible causes:

-- EMERGENCY STOP button defective



-- Exchange KCP


3.6.5

Space Mouse does not work

Possible causes:


-- Space Mouse defective

-- MFC defective (CAN bus)



-- Exchange KCP

-- Exchange MFC


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3.7

Fault profiles related to a field bus card

3.7.1

Communication via diagnostic interface not possible

Possible causes:

-- Data cable, periphery faulty

-- Diagnostic interface on field bus card defective


-- Take appropriate measures on data cable, periphery

-- Exchange field bus card

3.7.2

Error message “xxxxx I/O driver configuration error”

Possible causes:

-- Field bus card incorrectly configured

-- Field bus card cannot be initialized

-- Incorrect configuration of the file IOSYS.INI


-- Check configuration


-- Check entries in IOSYS.INI

3.7.3

After inserting the field bus card: no display, controller does not boot (Stop 0)

Possible causes:

-- Field bus card defective

-- Field bus card interferes with MFC function



3.7.4

The controller “hangs” after initialization of the field bus card

Possible causes:

-- Field bus card defective



3.7.5

No external power supply for slave when controller switched off

Possible causes:

-- Interbus filter defective or not correctly connected

-- External power supply input on IBS card defective


-- Exchange Interbus filter (if fiber--optic cable)

-- Exchange Interbus card


4

4.1

4 Servo drive module messages and error displays

Servo drive module messages and error displays

In the event of a drives error, messages are displayed in several ways.

Servo drive module LEDs (KSD1)

The operating state of the KSD is indicated by two LEDs on the front.

RD GN

Fig. 1 Servo drive module LED indicators

Red LED

Off

On

Green LED

Off

Off

Flashes quickly Flashing quickly (UIC > Ulimit)

Flashes slowly Flashing slowly (UIC < Ulimit)

Flashing quickly (UIC > Ulimit)

Meaning (message/fault)

No 24 V voltage

Undefined drive servo state

Fault present

Message is present (except in case of undervoltage UIC) [default value is 250 V]

Red LED

Off

Off

Off

UIC:

Ulimit:

Green LED

Flashes slowly

Flashes quickly

On intermediate circuit voltage intermediate circuit voltage = 250 V

Meaning (no message/fault)

UIC < Ulimit

UIC > Ulimit

Servo enable, UIC > Ulimit


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4.2

KCP messages for drives diagnosis

The following KSD error messages are displayed in the message window of the KCP.

Display in message window

DRIVES ERROR

Ax No.: TRIP

OVERCURRENT

Ax

Meaning/ cause of error

KSD is in a fault state; robot carries out Emergency Stop.

1. Overloading of the axis

2. I

2 t overload

3. KSD defective

Troubleshooting/ possible fault elimination

See detailed error message which is also displayed.

Reduce load on axis

(reduce OVR, $ACC_AXIS), exchange KSD.

SYNCHRONISA-

TION ERROR

DRIVE MODULE

Ax

Checksum error in the control unit device set

Microcontroller crash

Communication error with the

EEPROM in the control unit


EEPROM in the power unit

Checksum error in the power unit device set

Check Interbus cable between DSE,

KPS and KSDs.

HEAT SINK

TEMPERATURE Ax

Check cabinet cooling circuit/fans; reduce load on axis

(reduce OVR, $VEL_AXIS or

$ACC_AXIS).

Parameter error

Ax PR1

Checksum error in parameter set 1

MOTOR CABLE Ax Power unit overcurrent

(short--circuit or ground fault), hardware monitoring

Ground fault, software monitoring

Check KSD/restart/exchange

Check motor cable/motor

Motor phase failure Check motor cable/motor FAILURE OF

MOTOR PHASE Ax

Drives error Ax no.: 105





Max. permissible number of communication errors with the servo bus exceeded.

Too many consecutive toggle bit errors; cause short--circuit braking.

Overtemperature, heat sink







5

5.1

5 KPS--600 messages and error displays

KPS--600 messages and error displays

KPS--600/10 and /20 LED indicators

There are six LEDs on the front of the KPS--600.

LED 1 (red) and LED 2 (green) indicate internal states of the KPS.

LED 3 (green) and LED 4 (green) are reserved for the safety logic and are not yet assigned.

LED 5 (red) and LED 6 (red) indicate the state of the brake control.

1

6

5

2

3

4

Fig. 2 KPS--600 LED indicator


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5.1.1

Meaning of LEDs 1 and 2

LED 1 (red)

OFF

OFF

OFF

Flashes at 6 Hz

Flashes at 3 Hz

ON

Flashes 5 times at 1.5 Hz

LED 2 (green)

OFF

Flashes at 1.5 Hz

ON

OFF

OFF

OFF any

Flashes 4 times at 1.5 Hz any

Flashes 3 times at 1.5 Hz any

Flashes twice at 1.5 Hz

Flashes once at 1.5 Hz any any

5

6

7

2

3

4

Priority* Meaning

Processor without power supply

1

Intermediate circuit voltage < 60 V

Intermediate circuit voltage > 60 V

Communication error

8

Brake error

Main contactor K1 stuck

Error in BEA signal

(signal for flow of current through the ballast resistor)

Ballast error

Overvoltage in intermediate circuit

Overtemperature in interior / heat sink

Fault in the low voltage supply

(27 V not present)

* If more than one fault occurs simultaneously, the fault with the highest priority is displayed.

(1 = highest priority, 8 = lowest priority)

5.1.2


LED 3

Off

On

LED 4

Off

On

Meaning

Robot brakes not activated

Robot brakes activated

Meaning

External axis brakes not activated

External axis brakes activated

5.1.3


Designation

V1

V2

State of the red LED

LED on

LED on

Meaning

General EMERGENCY STOP activated

Local EMERGENCY STOP activated


5 KPS--600 messages and error displays (continued)

5.1.4

KPS--600 error messages on the KCP

Display in message window Meaning/cause of error

Parameter error PMx checksum

Parameter error PMx

Control

Drives error PMx no.: 71

Ballast switch energized for too long PMx during charging

Ballast switch energized for too long PMx

Heat sink temperature

PMx

Cabinet temperature too high

PMx

Drives error PMx no.: 79

Watchdog power module PMx Max. permissible number of communication errors with the servo bus exceeded, causes short--circuit braking

Overvoltage PMx during charging

Overvoltage PMx

Undervoltage PMx




Ixt overload of the brake resistor during charging

Ixt overload of the brake resistor during operation


Overtemperature, interior


EEPROM in the control unit

Overvoltage in intermediate circuit while charging

Overvoltage in intermediate circuit during operation

Low--voltage supply undervoltage

Troubleshooting/ possible remedy

Restart/exchange KPS



Ballast resistor defective or not correctly connected

Ballast resistor defective or not correctly connected; deceleration phases in robot program too long; use energy recovery unit

Cabinet ventilation is not working

Cabinet ventilation is not working


Check field bus -- drives cable

Mains voltage too high (transformer may be necessary)

Mains voltage too high; ballast switch defective >> exchange

KPS

Check low--voltage supply

(rated voltage 27.1 V)


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Display in message window Meaning/cause of error

Buffer battery voltage low

Check battery PMx

Undervoltage PMx during charging

Brake error

Ax/PMx channel x

Brake error

Ax/PMx channel x

Intermediate circuit charging circuit defective PMx

K1 contactor welded PMx

Battery undervoltage,

U<22 V

Battery undervoltage,

U<19 V

Undervoltage in intermediate circuit while charging, 500 V threshold not reached

Brake error, main axes

Troubleshooting/ possible remedy

Charge battery

Charge battery

Exchange battery

Mains voltage too low

Brake error, external axes

Brakes not connected or short--circuit on the brake cable

Brakes not connected or short--circuit on the brake cable

Restart/exchange KPS Optocoupler for ballast resistor current detection signals that no current is flowing

Main contactor K1 stuck Exchange KPS

The mastering can be saved manually via the KUKA HMI.

Before changing the battery: Setup > Master > Save current data


6

6 KPS--27 operating state indicators

KPS--27 operating state indicators

On the front of the KPS--27 are two LEDs which indicate the operating states of the low--voltage power supply unit:

LED indicator

Green LED (OK)

Red LED (overload)

Red LED (overload)

State

Lit

Lit

Flashes slowly

Meaning

Normal operation

Overload operation

Short--circuit operation


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DSE--IBS operating state indicators

When the DSE--IBS is plugged in, the green diagnostic LED is on the upper side. The meaning of the LEDs is explained in the following table:

Green LED Meaning

Off Servo program not active

Lit Error

Flashing Servo program active – operating state OK *

* The LED display is only meaningful once the controller has booted.


8

8 RDC2 operating state indicators

RDC2 operating state indicators

There are two diagnostic LEDs on the RDC2.

The meaning of the LEDs is explained in the following table:

LED indicator State

Off

On

Flashing

On

Meaning

No power supply

3.3 V power supply OK

RDC not yet ready (boot procedure)

RDC ready for operation

1

2

1 Green diagnostic LED 2

Fig. 3 LED indicators on the RDC2

Red diagnostic LED


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ESC diagnostic tool

The computer--aided safety system “ESC” (Electronic Safety Circuit) allows the permanent monitoring of all connected ESC circuit nodes. These include safety--related elements, such as Emergency Stop buttons or operator safety.

ESC diagnosis is supported from controller version “KR C2” onwards.

Only the safety circuit of the controller itself can be monitored.

Open the “Monitor” menu and select the command “Diagnosis” --> “Securitycircuit”.

The ESC diagnosis window is then displayed. The type and number of nodes available depend on the periphery used.

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Fig. 4 Example: KR C2 standard configuration with KCP, KPS--600, MFC and CI board


9 ESC diagnostic tool (continued)

The safety circuit units present are shown in the display. The passive MFC node is not displayed. The CI board does not have a node.

The current node is highlighted by means of a selection frame (focus). Special node states are indicated in color.

ESC diagnosis can also be started without the robot controller running. To do so, open the

Windows Start menu and select the option ”Run”. Enter the following command in the input line in the Run window:

“C:\KRC\Util\ESCView.exe”

9.1

Softkey bar

Pressing the softkey “Previous” places the “focus” on the next node down, thus selecting it as the current element.

If the current node has the number “1”, the node with the highest number is selected.

Pressing the softkey “Next” causes the next node up to be selected, thus making it the current element. If the current node has the highest possible number, the node with the number “1” is selected.

The softkey “State” is used to open the status indicator of the safety circuit. Data relevant to the selected node are listed here.

Information about the selected node. Settings can be made using the softkey “Configure” or in the file “ESCDiag.ini”.

The states of an individual node and its values can be viewed here.

The values are updated cyclically.

If the node has a special state, i.e. it is highlighted in color, the reason can be viewed here (in this example, the drives must be activated and the enabling switch pressed).

Descriptions of the last state changed (in this example, the panic position has been pressed and released again).

This softkey opens the error display. Errors that are not assigned to any particular node are displayed here. These include communication errors in the safety circuit as well as hardware and software errors.


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Information about the selected node.

Entries can be made using the softkey “Setup”.

List of all errors that have occurred.

Description of the selected error.

At Expert level, certain settings can be made for a specific node using the softkey “Setup”.

Global settings for the following entries:

Path of the icons used

Node color in event of error (default “red”)

Node color in normal state (default “pale gray”)

Settings for the specific node:

Icon file

2 info lines displayed in the node display

Comment

While ESC diagnosis is open, keep this window constantly in the foreground.

The settings of the “Setup” window are stored in the file “C:\KRC\Roboter\Init\ESC-

Diag.ini”.

If errors occur while loading the .ini file, an error message is generated.

For entries that cannot be evaluated, the default values are used.

This softkey is used to close the “State”, “Error” and “Setup” windows or terminate ESC diagnosis.

9.2

ESC diagnosis error messages



9 ESC diagnostic tool (continued)

Safety circuit diagnosis display Corrective measure

Byte timeout during receipt of log Check bus wiring

Checksum error in log

Invalid header byte

Check bus wiring

Check bus wiring

Interface error

Mode error

No log received

Initialization error

Configuration error

Hardware fault

PICA/PICB

Communication error

Software error

I/O monitoring error

RAM error

Relay error

Check bus wiring

Both operating modes active

Only one operating mode may be selected.

Check bus wiring

Two KCPs in the ESC circuit! Only one KCP

(master) may be present in the circuit.

Wrong configuration on ESC master (KCP).

Exchange KCP.

General message

ESC chip from which the message comes

Check bus wiring

Exchange module with software error

Check wiring to external contactor

Exchange module

Output error

Output error, operating mode

Output error, drives contactor

(auxiliary contact)

Output error, local E--Stop

Two modules are active or relays on the module are stuck

General message

Relay error (operating mode)


(auxiliary contact)

Relay error (EMERGENCY STOP)

Output error, AE coil

Cross--connection error at:

Local E--Stop


External E--Stop


Operator safety

Cross--connection error at: Qualifying input


Enabling switch 1

Cross--connection error at: Mode selector switch


E2 keyswitch


Short--circuit TA24(A) / TA24(B). Check wiring of the input for local E--Stop (NA)

Short--circuit TA24(A) / TA24(B). Check wiring of the input for external E--Stop (ENA)

Short--circuit TA24(A) / TA24(B). Check wiring of the input for operator safety (BS)

Short--circuit TA24(A) / TA24(B). Check wiring of the input for qualifying input (QE)

Short--circuit TA24(A) / TA24(B). Check wiring of the input for enabling switch 1 (ZS1)

Short--circuit TA24(A) / TA24(B). Check wiring of the input for operating mode (Auto/Test)

Short--circuit TA24(A) / TA24(B). Check wiring of the input for keyswitch E2

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Safety circuit diagnosis display


Enabling switch 2


Activate drives or Drives enable

Corrective measure

Short--circuit TA24(A) / TA24(B). Check wiring of the input for enabling switch 2 panic position

(ZS2).

Short--circuit TA24(A) / TA24(B). Check wiring of the input for Activate drives (AA) and Drives enable (AF).


10 DSE--RDW diagnostic tool

10 DSE--RDW diagnostic tool

This service option offers you a range of options for displaying states and fault diagnosis as well as for configuring the DSE--RDW part of the robot system.

10.1

Main menu of the DSE--RDW diagnostic tool

Navigate within the menus using the mouse, or use the keypad to enter the number preceding the menu text. The “ESC” key takes you up a level in the menu structure. Pressing the

“ESC” key at the top menu level exits the diagnostic tool.

Only alter the configuration settings if you have adequate knowledge of its function, and of the consequences of the alteration!

The contents of the EEPROM in the RDC unit can be overwritten.

These data cannot be restored simply by booting the system.

Setup > Service > DSE--RDW


Softkey assignment:

-Recognize hardware

Initiates the update of the data in the display boxes.

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10.1.1 Language selection

The language for the menus is selected via:

DSE--RDW > Language > [desired language]:

Display in the status line:

-Version number of the DSE--RDW diagnostic tool

-Type of control cabinet

-Current value of the DSE interrupt counter: incrementation of the counter indicates that the DSE control program is running correctly.


10 DSE--RDW diagnostic tool (continued)

10.1.2 System info

Displays the operating state of the DSE.


Display box assignment:

-Driver state: program is being executed

-Control type: type of controller (KR C1, KR C2, KR C3)

-MFC: version of the MFC module used

-1. DSE: type of the first DSE module

-State: operating state of the DSE module

-DPRAM test: result of the dual--port RAM test

-RDW: type of RDC module used

There is no second DSE present in this case; the four display boxes are identical to those for the first DSE.

Softkey assignment:

-Recognize hardware

Initiates the update of the data in the display boxes.

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10.1.3 MFC2 register display

Displays the contents of the MFC register.


-MFC: version of the MFC module used

-Remaining display boxes: development data

Softkey assignment:

-Start continuous display

Start / stop the continuous updating of the display

-Refresh

Triggers a one--off update of the display



10.1.4 DSE IBS information

Displays DSE hardware and software versions.


-Control type: type of controller (KR C1, KR C2, KR C3)

-DSE hardware: hardware version of the DSE

-DSE Clock Speed: clock frequency of the DSE used

-Remaining display boxes: internal version numbers


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10.1.5 Display RDC table

Displays RDC measurement and configuration data.

Softkey assignment:



-Refresh


-Export

Saves the current RDC table to the hard drive

-Page up / Page down

Navigation within the table

Data concerning the hardware configuration of the RDC are listed in the table from line 88 onwards.



10.1.6 RDC offset and symmetry adjustment

Displays the adjustment data for all axes.

Adjustment of the following values is carried out automatically.

-Sine offset

-Cosine offset

-Sine calibration

-Cosine calibration

In order to be able to determine the sine and cosine values correctly, every axis must have been moved through several revolutions of the motor.

Softkey assignment:

-Set default values

The default values should be set if motors or the RDC module have been exchanged, or if sporadic encoder errors have occurred.


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10.1.7 Check RDC--DSE communication

The RDC sends data words to the DSE in a 125 µs cycle. This function can be used to check the communication between the DSE and the RDC.

Meaning of the values displayed in the message window:

-Order: The last command the DSE has sent to the RDC.

-Value: Motor temperatures of axes 1 to 8.

-Error: Encoded display of the encoder error bits and EMT signals

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EMT Encoder error bits for the robot axes signals A8 A7 A6 A5 A4 A3 A2 A1

-Checksum: Checksum for all transferred data.

--

Communication error state:

If more than three transmissions have failed, the value 0001 is displayed.

--

Communication error counter:

Sum of all incorrect transmissions since the last “Reset comm. errors”.

-Axis nn: Displays the resolver positions of axis nn. The values vary during operation. If a resolver position has the value zero, there is an encoder error.

Softkey assignment:



-Refresh



10.1.8 Drive bus diagnostics



The values displayed in the message window have the following meaning:

-Number of cycles: number of data transmissions between DSE and RDC since system switched on / reset

-Data errors: number of data errors in the data transmissions between DSE and

RDC (sporadic errors)

-Data errors in series: number of consecutive data errors following the first three

-Ident errors: number of errors during transmission

Softkey assignment:



-Refresh


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10.1.9 Drive bus error list

Displays the error statistics with the drive bus running.

Softkey assignment:



-Refresh


-Reset cycle counter

-Reset errors

-Reset error list


10.1.10 Drive bus diagnostics -- KPS--2



Softkey assignment:



-Refresh


-Export code table

Saves the current code table to the hard drive

(example: C:\KRC\Roboter\Log\Drivebus1--4_KSD1--8.log)


-Lecom error

Lenze communication error number

-Hardware version of control and power unit

-Various voltages, currents and temperatures of the KPS

-Operating time counter: intermediate circuit has been active for xx hours

-Power--on time counter: KPS--2 has been active for xx hours

-1st and 2nd code position:

Polling of the current error memory and the last three history entries:

Code position 161: current error

162: current error --1



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10.1.11 Drive bus KSD 1--16

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Softkey assignment:



-Refresh


-Export code table

Saves the current code table to the hard drive

(example: C:\KRC\Roboter\Log\Drivebus1--4_KSD1--8.log)


-Lecom error

Lenze communication error number

-Hardware version of control and power unit

-Various voltages, currents and temperatures of the KSD

-Operating time counter: intermediate circuit has been active for xx hours

-Power--on time counter: KSD 1--16 has been active for xx hours

-1st and 2nd code position:

Polling of the current error memory and the last three history entries:

Code position 161: current error






10.1.12 Error messages valid for the KPS--600

Message text

5

6

8

1

3

10

39

24

IBS trip number Lecom error number

0 0

72

105

71

11

15

50

52

79

“ok”

“Pr1--Trip”

“HO5--Trip”

“CCr--Trip”

“OC1--Trip”

“OC5--Trip”

“OH--Trip”

“OH2--Trip”

“Pr5--Trip”

28 65 “CE4--Trip”

41

30

37

40

35

36

19

31

32

33

34

141

142

112

111

131

132

32

121

122

123

124

“OV1--Trip”

“OV2--Trip”

“LP1--Trip”

“LV1--Trip”

“LV2--Trip”

“LV3--Trip”

“LV4--Trip”

“BR1--Trip”

“BR2--Trip”

“BEA--Trip”

“K1--Trip”

Meaning

Device state OK




Ixt overload of the brake resistor while charging

Ixt overload of the brake resistor during operation


Overtemperature, interior

Communication error with the EEPROM in the control unit

Max. permissible number of communication errors with the drive bus exceeded, causes short--circuit braking

Overvoltage in intermediate circuit while charging

Overvoltage in intermediate circuit during operation

Mains phase failure

Low voltage supply undervoltage

Battery undervoltage, U<22 V

Battery undervoltage, U<19 V

Undervoltage in intermediate circuit while charging, 500 V threshold not reached

Brake error, main axes

Brake error, external axes

Optocoupler for ballast resistor current detection signals that no current is flowing

Main contactor K1 stuck


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10.1.13 Error messages valid for the KSDs

(valid from Firmware V0.3 onwards)

Message text

3

5

0

1

6

IBS trip number Lecom error number

0

72

105

71

11

“ok”

“Pr1--Trip”

“HO5--Trip”

“CCr--Trip”

“OC1--Trip”

7

8

10

11

12

15

50

91

“OC2--Trip”

“OC5--Trip”

“OH--Trip”

“EEr--Trip”

19

24

28

32

79

65

“LP1--Trip”

“Pr5--Trip”

“CE4--Trip”

43

44

80

106

“PR6--Trip”

HO6 trip

Meaning

Device state OK




Power unit overcurrent (short--circuit or ground fault), hardware monitoring

Short--circuit, software monitoring

I*t overload


External error, short--circuit braking requested by the controller

Motor phase failure

Communication error with the EEPROM in the control unit

Max. permissible number of communication errors with the drive bus exceeded, or too many toggle bit errors in succession, causes short--circuit braking.

Communication error with the EEPROM in the power unit

Checksum error in the power unit device set


11 Oscilloscope

11 Oscilloscope

The submenu “Oscilloscope” contains the two additional menu items “Display” and

“Configure”.

Using the menu key “Monitor”, open first the submenu “Diagnosis” and then the menu

“Oscilloscope”. The following submenu is displayed:

The commands in the menu bar are deactivated and cannot be selected while the oscilloscope is being displayed or configured.

11.1

Display

This function allows you to display and analyze saved traces.

A window is opened on the display. All files which are archived in the directory

C:\KRC\Roboter\TRACE and have the extension TRC are displayed here.


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11.1.1 File selection

2nd file

The desired file can be selected using the arrow keys. The name of the selected file is indicated by a color highlight. Move the cursor to a file having the end digit “1”. It contains data from the digital servoelectronics DSE (“3” = I/O data, “4” = interpolator data, “%” = test data).

After selecting this file, please press the softkey “Ok”.

The oscilloscope display is opened.

The softkey “2nd file” is described in more detail in the section [Superposing traces].

11.1.2 Oscilloscope screen

The contents of your screen should now look similar to those below. However, you have probably recorded other data with a different configuration. For this reason, the individual curves also have different forms and different colors on your screen.

White

Magenta

Yellow

Brown

Cyan

Active color: Blue

More detailed information about the curves can be found in the upper part of the display. The color, the name, the unit of measurement and the scale of the display are listed in sequence for each curve.

The left bar (vertical) shows values which, when multiplied by the scale of the display, represent the value of a curve at a point in time that is shown below on the time axis

(horizontal).

If signals from the controller’s inputs and outputs are displayed, the left bar (vertical) contains numbers as placeholders for the number of the selected inputs or outputs.

Inputs or outputs are only displayed while they have the value “TRUE”.

While an input or output has the value “FALSE”, only a broken gray line is displayed.


White

11 Oscilloscope (continued)

Red

Active color: White

The “active” color is permanently displayed at the bottom left of the screen.

You can “move” through the entire trace by using the arrow keys.

You can exit the display function again at any time by pressing the softkey “Cancel”.

11.1.3 The information window

Now press the softkey “Info”. A window is opened displaying further information about the individual curves. The information window appears as follows for the example given above:


The color and the number of each curve are displayed in the first column.

The second column specifies the file from which the data for the curve have been read.

You can see the channel to which the curve has been assigned and the variable that it represents in the columns “Channel” and “Name”.

The name of the color of the curve is displayed in the column “Color”.

The last column indicates whether the curve is visible or hidden.

Press the softkey “Info” again. The window is closed. You can switch between the two functions by using this softkey.

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11.1.4 The softkey bar

The softkey bar has four levels in the function “Display”.

You can switch between these four levels by using the softkey “===>”.

11.1.5 The color softkeys

To make it as easy as possible to read the display, a maximum of eight different colors (blue, green, white, red, magenta, brown, yellow and cyan) are shown.

Curves can be displayed or removed on the basis of their colors with the aid of the color softkeys. This is done quite simply by pressing the appropriate color softkey.

Hide the blue curve, for example, by pressing the softkey “Blue”. Then open the information window. Reminder: To do so, press the softkey “Info”.

Your action has been registered in the last column (far right). “Visible” now has the value “No” for the blue curve.

Close the information window again and then make the blue curve visible once more. To do so, press the color softkey “Blue” again.

If you press color softkeys while the information window is open, color assignments will be canceled. The procedure for recovering canceled color assignments is described in the section [Changing color assignments, Section 11.1.14].

Certain graphs can be removed by selecting the desired graph in the information window and pressing the “Enter” key. More detailed information on this can be found in the section

[Switching curves on and off, Section 11.1.15].



11.1.6 The scaling function

In the display, you are able to increase or reduce the amplitude of individual curves.

To do so, press the softkey “Channel” until the color of the desired curve is active. The active color is permanently displayed at the bottom left of the window.

N

M


Now observe what changes occur when you press the keys “M” or “N” in the ASCII alphabetic keypad.

Pressing the key “N” in the ASCII alphabetic keypad gradually increases the amplitude.

Pressing the key “M” in the ASCII alphabetic keypad gradually decreases the amplitude.

By using this function, it is also possible to clearly display curves which only have a small deflection or which are hidden by other curves.

The current scale is given in the top area of the display.

White

Magenta

Yellow

Green

Red

Cyan


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11.1.7 The zoom function

Press the softkey “===>” repeatedly until the following softkey bar appears.

When the softkey “Zoom” is pressed, a white cross about five millimeters high appears in the middle of the window. This can be moved about the entire window using the arrow keys. Move it to the position of your choice and then press the Enter key. The point that is currently selected represents a corner point of the zoom window, which must now be expanded using the arrow keys. Include everything that you want enlarged in this zoom window and then press the Enter key again. The contents of the zoom window will then be enlarged on the display.

To undo zooming, please press the softkey “Unzoom”.

11.1.8 The Save function

Press the softkey “===>” repeatedly until the following softkey bar appears.

This softkey saves the current oscilloscope display as a bitmap on the hard disk. It is saved as a BMP file in the directory “C:\KRC\Roboter\Trace\”. The file name corresponds to the name of the trace or the loaded file. This file can then be viewed in a graphics program (MS

Paint, Picture and Fax Viewer).

11.1.9 The r.m.s. value function

In order to determine the value that a curve represents during a certain period of time as easily as possible, the r.m.s. value function has been integrated.

To determine the r.m.s. value, you must press the softkey “Channel” to select the color used by the curve that is to be evaluated. The active color is permanently displayed at the bottom left of the window.


Then press the softkey “RMS”. A vertical white line with the label “Evaluation of RMS” is displayed in the window


White

Magenta

Yellow

Evaluation of RMS


Brown

Cyan

Active color: Magenta

Now move this line to the start point of your r.m.s. value evaluation using the “←” and “→” arrow keys and then press the Enter key.

You can now use the “←” and “→” arrow keys to define a sort of “measuring range”, which is displayed as a white box.

White

Magenta

Yellow

Red

Cyan

Evaluat ion of RMS



After pressing the Enter key, the result of the evaluation is displayed in the window.

Should the text that is displayed be concealed by other curves and thus cannot be read, simply hide the other curves for the time being. Reminder: To do so, use the color softkeys.

To end the “RMS” function, press the softkey “RMS” again.

If you press the softkey “Cancel” instead, the entire display function will be ended.

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11.1.10 Print

If you would like to print out the contents of the screen, please press the softkey “Print”.

The screen is printed on the current default printer of the operating system; the printer should be set to “Landscape”.

11.1.11 The cursor functions

Press the softkey “===>” repeatedly until the cursor functions appear in the softkey bar.

Using these functions, you can place two vertical and two horizontal lines (cursors) inside the window. This enables you to determine the value that a curve represented at a certain time quite easily.

The color of the active curve is permanently displayed at the bottom left of the window. To change it, press the softkey “===>” repeatedly until the following functions appear in the softkey bar.

Press the softkey “Channel” until the color of the desired curve is active.


Change the softkey bar again and then press the softkey “VCursor1”. A vertical white line is displayed in the window.

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The value that the selected curve had at the time where the cursor is currently positioned is displayed at the top left of the window (two values are displayed in this illustration as the softkey “Filter off” has been selected). When inputs or outputs are displayed, the bit pattern of the selected input or output group is displayed.


Now move the cursor using the arrow keys and observe how the top left of the display changes.

Press the softkey “VCursor2”. A second vertical white line (cursor) is displayed in the window.



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The values for the second cursor now appear to the right of the display for the first cursor.

Two values are displayed in this illustration, one below the other, as the softkey “Filter off” has been selected. When inputs or outputs are displayed, the bit pattern of the selected input or output group is shown here as well. The time difference between these two cursors is displayed on the left--hand side.

These cursors can be removed again by pressing the softkey “VCursor1” or “VCursor2” once more.

If you press the softkey “HCursor1”, a horizontal white line (cursor) is displayed in the window.

When inputs and outputs are displayed, the function “HCursor” is not suitable for showing the numbers.

White

Magenta

Green

Brown

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The value where the cursor is currently positioned is displayed at the top left of the window.

Now move the cursor using the arrow keys and observe how the top left of the display changes.

Press the softkey “HCursor2”. A second horizontal white line (cursor) is displayed in the window.

When inputs and outputs are displayed, the function “HCursor” is not suitable for showing the numbers.


White

Magenta


Green

Brown


The values for the second cursor now appear to the right of the display for the first cursor.

The difference between these two cursors is displayed on the left--hand side.

These cursors can be removed again by pressing the softkey “HCursor1” or “HCursor2” once more.

11.1.12 The filter function

By pressing this softkey, you can switch on a software filter which “smoothes” the displayed curves. This filter is switched off again by pressing this softkey once more.

unfiltered filtered


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11.1.13 Superposing traces

To allow you to compare data from different traces with each other, the function “2nd file” has been integrated.

To do this, open the menu using the menu key “Monitor”. Then select “Diagnosis”. The following submenu is displayed:

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As you want to use the oscilloscope function “Show” to view traces that have already been saved, please confirm the offered selection “Oscilloscope”. A further menu is opened, in which you also confirm the offered selection “Display” again.

A window is opened on the display. All files which are archived in the directory

C:\KRC\ROBOTER\TRACE and have the extension TRC are displayed here.

The desired file can be selected using the arrow keys. The name of the selected file is indicated by a color highlight. Move the cursor to a file having the end digit “3”. Data from the controller’s inputs and outputs are recorded in this file.


2nd file


After selecting this file, please press the softkey “2nd file”. Beneath the trace file list appears the message “BEW31.TRC marked for second file, please choose first file and hit “Ok”.

Now use the arrow keys to move the cursor to a file with the end digit 1, for example.

After selecting this file, please press the softkey “Ok”.

In the window, you can now see that the contents of these two traces are superposed on each other.

White

Magenta

Red

Green



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11.1.14 Changing color assignments

The color assignments of the individual curves can be changed at any time. This is necessary, for example, if more than 8 channels are assigned and not all channels can be displayed simultaneously because there are only 8 colors available. To do so, open the information window by pressing the softkey “Info”.

As an example, we now want to interchange the color assignments of curves 1 (currently still blue) and 3 (currently still red).

Press the color softkey “Blue” to deactivate the assignment that is valid for the curve.

Move the highlight to the curve with the number 3.

Press the color softkey “Blue” again to assign the color blue (which has just become available) to curve 3.

Move the highlight to curve 1, which is currently not assigned a color.

Press the color softkey “Red” here to assign the color red to this curve.

Now close the information window again.



11.1.15 Switching curves on and off

It can sometimes be necessary to completely remove individual curves from the display. To do so, open the information window by pressing the softkey “Info”.

Select the curve that you would like to remove from the display. The curve that is currently selected is highlighted by a color background. Now press the Enter key.

Now close the information window again.

As you can see, your action has been registered. The deactivated curve is now no longer displayed.


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11.2

Configure

Before you can record something with the oscilloscope, you must first tell it WHAT and HOW it is to record. For this purpose, the oscilloscope function offers a range of configuration options.

A window is opened on the display. Data which characterize the trace in greater detail must be entered here.

The combo boxes “Interpolator data” and “Test data” are only available at Expert level or above.




The various input boxes can be selected using the “←” and “→” arrow keys. Then enter the desired values by means of the keyboard or numeric keypad.

If you only wish to change a few of the characters in the selected entry, press the “↓” or

“↑” arrow keys to remove the highlight. Then proceed using the arrow keys as usual.

The combo boxes can be opened by pressing “ALT” + “↓” or “ALT” + “↑”. Alternatively, you can page through the existing combo box entries using the “↓” and “↑” arrow keys.

Softkeys:

The softkey “DSE Table” is used to toggle to the DSE table. Here you can determine which data (e.g. actual velocity) are recorded for specific axes.

The softkey “I/O Table” is used to toggle to the I/O table in which settings are made for the inputs/outputs to be recorded.

Recording is started manually irrespective of the selected trigger condition by pressing the softkey “Trigger”.

Recording is started by pressing the softkey “Start”. It begins as soon as the selected trigger condition is met.

Recording is stopped by pressing the softkey “Stop”. All of the data that have been recorded thus far are saved.

The current configuration is saved by pressing the softkey “Save”. It is available next time the oscilloscope function is opened.

If a trace has been made, you do not need to save the configuration separately as it is saved automatically with the name of the trace.

The softkey “Show” has the same function as the menu key “Monitor” followed by the submenu “Diagnosis” and the option “Display”. Details can be found in Section 11.1.

The window for configuring the oscilloscope is closed by pressing the softkey “Cancel”. The entered values will not be saved.

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11.2.1 General

The name and length of the trace are specified in this window.

Name of recording

A file name under which the trace will be saved later can be defined here. Do not use more than seven characters because a further digit is added to the file name by the system in order to distinguish different types of trace.

4

5

1

3

These trace files, with the extension TRC, can be found in the directory C:\KRC\ROBO-

TER\TRACE.

The numbers for the different trace types have the following meaning:

DSE data

Data relating to inputs/outputs

Interpolator data

Test data

Length of recording

Please enter an integer value here specifying the length of the trace in seconds.

If the entry exceeds the maximum permissible trace length (default: 999 seconds), a message is generated in the message window when the recording begins. If this happens, change the value accordingly.

The cycle rate for recording DSE data is 2 ms. 500 data sets are therefore generated per second. Please take this volume of data into account when programming the length of the trace.



11.2.2 Trigger condition

The position in time and the trigger condition for the trace are specified in this box.

Pre--Trigger

Specify the position in time of the trace in relation to the trigger time in this box. The value between 0% and 100% that is entered refers to the programmed trace length.

Time

Recording of data from the trigger time

Recording of data is already started before the trace is triggered (from 50% of the programmed trace time)

Recording of data up to the trigger time

100%

50%

0%


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Trigger event

In this field, select the event which will trigger recording.

Trigger on I/O state

The recording starts when the defined input/output assumes the specified state.

The I/O and the state must be defined.

Start by user, recording until buffer is full

The recording must be initiated manually with the softkey “Start”. It continues until the set recording length has been reached.

Cyclical recording until user stop

Recording is carried out for the time specified in “Length of recording” before termination with the softkey “Stop” is recorded.

Trigger on error

Recording is carried out for the time specified in “Length of recording” before and after the occurrence of an error that stops the robot system. The location of this period of time depends on the value set as the trigger moment.

Trigger on motion start

The recording starts whenever the beginning of a motion instruction is reached or a motion instruction is being executed. It continues until the set recording length has been reached. The location of this recording time depends on the value set as the trigger moment.

Trigger on clearing filter

This option is intended for our service personnel only.

Trigger on DSE error

In this instance, recording is carried out for the time specified in “Length of recording” around the appearance of a DSE error that is signaled by the digital servoelectronics (e.g. “Command value out of range”, “Cabinet temperature too high”). The location of this period of time depends on the value set as the trigger moment.



11.2.3 Trace status

The current working status of the oscilloscope can be seen in this field.

Trace status

#T_WAIT

#TRIGGERED

#T_END

Meaning

Trace is started and is waiting for the trigger condition. All of the data before the trace is triggered are recorded.

Trace is triggered and runs for as long as specified in the boxes “Length of recording (sec)” and “Trigger moment”.

Trace is finished, the data are saved on the hard disk.

11.2.4 Trace data

This box is used to define the data to be recorded.

Comment

You can enter a comment here, e.g. relating to the oscilloscope configuration.


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DSE (Digital Servo Electronics) card

Here you can select if you want to record data of DSE 1 (axes 1--8) or DSE 2 (axes 9--16).

If you do not want to record any DSE data at all, please select the option “No DSE data”.

Files containing the traces of DSE data are identified by the end digit “1” in the file name.

The cycle rate for recording DSE data is 2 ms. 500 data sets are generated per second.

Pressing the softkey “DSE Table” opens a window in which the values to be recorded are listed.

Here you can define the values and axes for which traces are to be made. This is done by navigating with the “↓” and “↑”, or “←” and “→” arrow keys. Selections are made by pressing the space bar.

It is also possible, using the softkeys, to select or deselect all axes for a particular value, delete the entire selection, or toggle to the I/O table or main group.

A maximum of 21 DSE channels are available at any one time.

If more than 21 channels are configured, the results will be incorrect.



Explanation of the individual values:

Values to record

Bus voltage PM1

Bus voltage PM2

Command value

Actual value

1)

Following error

1)

1)

Command velocity

1)

Actual velocity

1)

Actual current

1)

Motor temperature

1)

Resolver

1)

Command current

1)

Torque differential

1)

1)

For each of the channels 1...8

Meaning

Power module 1

Power module 2

Command value from the interpolator per position control cycle

Actual value per position control cycle

Difference between command position and actual position

At the position controller output

Motor speed

Current sensors

In increments

Encoder position

At the speed controller output

Value calculated from the command/actual current


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I/O group

Here you can choose to record “No I/O data”, “I/O data” or the 32 cyclical flags. Select the desired function in the combo box. In order to record I/Os, it is necessary to open the I/O table using the softkey “I/O Table” and define the desired input/outputs.

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Move around this window as described above.

With the setting “Channels 1/2”, channels 1--16 can be processed, and with the setting

“Channels 3/4”, channels 17--32 can be processed.

Define the individual oscilloscope channels by input/output and enter the number.

Unlike with previous software versions, it is now possible to record any 16 inputs or outputs simultaneously. This means, for example, that inputs [1], [65] and [250] can be recorded at the same time.

Files containing traces of the status of inputs and outputs are identified by the end digit “3”.

The cycle rate for recording the activities of inputs and outputs is 12 ms. About 85 data sets are generated per second.

Here also, it is possible, using the softkeys “DSE Table” or “Main”, to toggle to the respective windows.

Interpolator data

The interpolator data include the Cartesian position of the robot (X,Y,Z,A,B,C), the path velocity and the geometric angles of axes 1--12.

You must now choose whether to record the “Actual values”, “Command values” or “No data”.

This function is only available in “Expert” mode.

Test data

These data are analyzed by KUKA Roboter GmbH. If problems occur, the customer can contact KUKA Support and create a corresponding file for evaluation by KUKA.

This function is only available in “Expert” mode.



11.2.5 Examples of a trace

As the oscilloscope function with all the configuration and display options is complex, we want to introduce you to the use of this tool with the aid of a few examples.

Example 1

The following are to be monitored: command speed of the drive of axis 1 actual speed of the drive of axis 1 status of outputs 1 to 16

Create a motion program which moves axis 1 and operates outputs 1 to 16.

Press the menu key “Monitor” and select the option “Diagnosis”. In the submenu which opens, please confirm the selection “Oscilloscope”. Now select “Configure”.

In the following boxes, select these settings:

Box

Name

Length of recording

Pre--Trigger (%)

DSE card

I/O group

Interpolator data

Test data

Entry

Trace1 (max. 7 characters)

12

0

Trigger on motion start

DSE 1

I/O

None

No test data

Press the softkey “DSE Table” to open the selection box for the DSE values to be recorded and select “Command velocity” and “Actual velocity”.

Press the softkey “I/O Table” to open the selection box for the I/Os to be recorded and select

“Channels 1/2”. Channels 1--16 must now be defined as inputs and numbered accordingly.

Now start the motion program and then press the softkey “Start”.

The command speed, the actual speed and the statuses of inputs and outputs 1 to 32 will now be recorded and saved until the data buffer is full and the trace status changes to

#T--END. The files are called TRACE1.trc and TRACE3.trc.


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Example 2

The signals of inputs and outputs 1 to 16 are to be recorded as soon as input 3 takes on the state “TRUE”.

Box

Name

Length of recording

Pre--Trigger (%)

I/O state

DSE card

I/O group

Interpolator data

Test data

Entry


10

0

Trigger on I/O state

$IN : 3 = TRUE

No DSE data

I/O

None

No test data


“Channels 1/2”. Channels 1--16 must now be defined as inputs and numbered accordingly

(1--16). Select Channels “3/4”, define channels 17--32 as inputs and number them (1--16).


Input 3 will now be monitored for occurrence of the trigger condition. The message

“#T_WAIT” is displayed in the box “Trace--status”. This message changes to

“#TRIGGERED” as soon as the trigger condition is fulfilled. The signals of inputs and outputs

1 to 16 will be recorded for 10 seconds from this moment onwards.




Example 3

A robot program branches to various subprograms depending on how the PLC sets specific signals. In a certain, unknown situation, the program branches to the subprogram

“SP55.SRC”, which is not desired in this configuration, however.

For the purpose of checking the I/O communication of the robot program with the PLC in this situation, an unassigned output (e.g. output 32) can be set in the subprogram SP55 and reset again on quitting the subprogram.

A trace can now be triggered at this output and the recorded sequence of events saved.

Box

Name

Length of recording

Pre--Trigger (%)

I/O state

DSE card

I/O group

Interpolator data

Test data

Entry


12

90 (since the “pre--event history” is of interest)

Trigger on I/O state

$IN : 32 = TRUE

No DSE data

I/O

None

No test data


“Channels 1/2”. Channels 1--16 must now be defined as inputs and numbered accordingly

(1--16). Select Channels “3/4”, define channels 17--32 as inputs and number them (1--16).


Output “32” will now be monitored with regard to this trigger condition. The message

“#T_WAIT” is displayed in the box “Trace--status”. This message changes to

“#TRIGGERED” when the trigger condition is fulfilled. The signals for inputs and outputs

1--16 are then recorded for 10.8 seconds before the trigger moment and 1.2 seconds after the trigger moment.

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Example 4

You discover that a robot program always stops at night because an error occurs in the I/O communication with the PLC. It cannot be determined whether this error is caused by the

PLC program or the robot program since nothing is known about the incorrect communication at this point.

It is possible for the oscilloscope function to be started in the KRL robot program before this situation and to be ended after it. The data are overwritten every time the program is correctly executed. If the motion program is interrupted by an error message, however, the last trace is saved and the error can be analyzed with the aid of the recorded data.

Box

Name

Length of recording

Pre--Trigger (%)

DSE card

I/O group

Interpolator data

Test data

Entry


Length of communication between robot and PLC taken into consideration.

0

Start by user, recording until buffer is full

No DSE data

I/O

None

No test data

As the communication between the controller and the PLC occurs via the I/Os, all affected inputs/outputs must be recorded. These are defined in the selection box which is opened using the softkey “I/O Table”.

Now save the configuration by means of the softkey “Save”, and quit the oscilloscope function by pressing the softkey “Cancel”.

Insert the following lines into the KRL program before the selected program section in order to start the trace:

$TRACE.MODE=#T_START

WAIT FOR $TRACE.STATE == #T_END

Insert the following lines into the KRL program after the selected program section in order to stop the trace:

$TRACE.MODE=#T_STOP

WAIT FOR $TRACE.STATE == #T_STOP

These changes can only be made at the Expert level.

As soon as the error has been located, these instructions must be removed from the program again.


12 Robot repair card

12 Robot repair card

You will be sent a Repair Card along with the spare parts requested from the KUKA Robot

Group.

Return the completed Repair Card to the KUKA Robot Group along with the defective exchange parts removed during the repair.

The data in the Repair Card will help us to speed up the reprocessing of the exchange parts.

The returned Repair Cards provide us with statistical data that are of great importance for

KUKA quality management.

D

A

I

M

E

Q

N

F

J

B

O

G

K

R

C

H

P

L

Fig. 5 Repair card

Box A

Please enter in this box the name of your firm and where it is based/the location of the plant in which the affected robot system is installed.

Box B

Describe the location of the robot system.

Example: Shop 4, UB I, IR 16 B

Box C

The order number is assigned to the robot system by the KUKA Robot Group when the order is processed. You can either obtain this number from your purchasing team or leave this box empty. The order number will then be entered later by the KUKA Robot

Group.


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Box D

Please enter here the type of robot in which the defective part or module was located.

The type designation can be found here:

Serial number

Fig. 6 Rating plate on robot base

Box E

The serial number of the robot system can be found here:

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Fig. 7 Rating plate

Box F

The serial number of the control cabinet can be found here:

KR C2

0122

00106204

2000

392.750--36...

3x400 V

50/60 Hz

6 A

16 A

185kg

12345

Fig. 8 Rating plate on control cabinet



12 Robot repair card (continued)

Box G

The serial number of the PC controller can be found on the front of the lower swing frame inside the control cabinet:

For safety reasons, the cabinet door may only be opened by a qualified electrician.

K C2

Fig. 9 Rating plate on the PC controller

Box H

Enter here the type of application for which the robot is used.

Box I

Enter here the name of the failed and replaced part.

Box J

Enter here the article number of the defective part.

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Box K

Enter in this box the serial number and, if possible, the manufacturer’s release of the failed part.

Box L

Enter in this box the serial number and, if possible, the manufacturer’s release of the replacement part.

Box M

Enter here the duration of downtime and the time required, in minutes, for repairing the robot system.

If the failure of the part or component did not cause any downtime, please mark the box

“No”.

Box N

Enter, in this box, the date on which the fault occurred.



12 Robot repair card (continued)

Box O

Enter, in this box, the value displayed on the operating hours meter at the time of the fault.

The number of operating hours can be obtained by dividing the value of the system variable $ROBRUNTIME by 60.

In order to read this system variable, press the menu key “Monitor” on the user interface and select the option “Modify variable” from the menu that is opened. The status window illustrated appears in the programming window.

List boxes are opened using the keyboard shortcut

ALT+↓ .

Fig. 10 Operating hours of the robot system

To display the value of a variable, position the cursor in the input box “Name”, using the softkey “Name” and enter the name of the variable you wish to change, in this case

$ROBRUNTIME. Then press the Enter key to confirm this.

The value of the variable is now displayed in the field “Current value”.

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Box P

In this box, let us know your name and the date on which the repair card was completed.

Please mark one of the two boxes to indicate whether you are a customer or an employee of the KUKA Robot Group.

Box Q

In this box you must specify the reasons for returning the part. Place a check mark in the relevant boxes.

If you would like to be informed of the results of our inspection of the returned part, enter a fax number, in the line provided below for this purpose, to which we can send you the requested information.

Box R

In this box, you should give a detailed description of the fault (e.g. error numbers, message texts, etc.).

1


A

Adjustment data, 45

AE coil, 37

Article numbers, 7

Axis load, 26

B

Ballast error, 28

Ballast resistor, 28, 29, 30

Battery change, 30

Boot procedure, 33

Brake cable, 30

Brake control, 27

Brake error, 28, 30

Bus wiring, 37

Byte timeout, 37

C

Cabinet ventilation, 29

Cause of fault, 8

CD--ROM, 7

Checklists, 8

Checksum error, 26, 29, 37

CI board, 35

Clock frequency, 43

Clock speed, 43

Code position, 49, 50

Code table, 49, 50

Color assignments, 66

Commissioning faults, 8

Communication error, 26, 28, 35, 46

Configuration data, 44

Configuration error, 37

Configure, 53

Cosine calibration, 45

Cosine offset, 45

Crosswise connection error, 37

Cursor functions, 60

Curves, 54

Customer repair, 7

Customer support personnel, 7

Cycle counter, 48

D

Data errors, 47

Data word, 46

Index

Diagnostic tool, 40

Display, 53

DPRAM, 41

Drive bus, 48

Drive bus diagnostics, 47

Drive bus diagnostics -- KPS--2, 49

Drive bus error list, 48

Drives diagnosis, 26

Drives enable, 38

Drives error, 25, 29

DSE, 15

DSE control program, 40

DSE IBS information, 43

DSE interrupt counter, 40

DSE--IBS, 32

Dual--port RAM, 41

E

EEPROM, 39

Electronic Safety Circuit, 34

Elimination of faults, 8

EMERGENCY STOP, 28

Enabling switch, 37

Error display, 35

Error memory, 49, 50

Error messages, 37

Error statistics, 48

ESC, 34

ESC chip, 37

ESC circuit, 34

ESC diagnosis, 34, 35, 36, 37

ESC diagnostic tool, 34

ESCDiag.ini, 35

ESD directives, 7

Exchange parts, 7, 81

Exchanging components, 8

Exchanging modules, 7

Expert level, 36

External axes, 28

F

Fault analysis, 8

Fault diagnosis, 39

Filter function, 63

Focus, 35

Index -- i

G

Ground fault, 26

H

Hardware detection, 39, 41

Hardware fault, 37

Header byte, 37

History entries, 49, 50

I

I/O group, 76

Ident errors, 47

Incorrect operation, 8

Initialization error, 37

Interface error, 37

Interference fields, 8

Intermediate circuit, 28

Intermediate circuit voltage, 28

Interpolator data, 54, 76

Isolation of faults, 8

K

KPS--27, 31

KPS--600, 27

KSD error messages, 26

KUKA service personnel, 7

L

Language selection, 40

Lecom error, 49, 50

LEDs, 27

Log, 37

Low voltage, 29

Low voltage supply, 28

Low--voltage power supply unit, 31

M

Machine data, 15

Menu language, 40

MFC, 20

MFC node, 35

MFC register, 42

MFC2 register display, 42

Microcontroller, 29

Mode error, 37

Index

Mode selector switch, 37

Modules, 7

Motherboard, 7

Motion program, 77

Motor phase failure, 26

N

New parts, 7

Node, 35

Nodes, 34

Normal operation, 31

Number of cycles, 47

O

Operating time counter, 49, 50

Optocoupler, 30

Order number, 81

Oscilloscope, 53, 77

Output error, 37

Overcurrent, 26

Overload operation, 31

P

Panic position, 35, 38

Parameter error, 29

PC rack, 7

PICA, 37

PICB, 37

Power unit, 26

Power--on time counter, 49, 50

Procurement of spare parts, 7

Q

Qualifying input, 37

Quality management, 81

R

RAM error, 37

RDC offset adjustment, 45

RDC symmetry adjustment, 45

RDC table, 44

RDC--DSE communication, 46

RDC2, 33

Receipt of log, 37

Relay error, 37

Repair, 7, 8

Index -- ii

Repair card, 81

Repairs, 7

Resolver position, 46

RMS value function, 58

Robot brakes, 28

S

Safety circuit, 34, 35

Safety logic, 27

Safety system, 34

Save function, 58

Scaling function, 57

Selection frame, 35

Service option, 39

Service personnel, 7

Service seminar, 7

Servo drive module, 25

Servo module LEDs, 25

Servo program, 32 short circuit, 26

Short--circuit braking, 26

Short--circuit operation, 31

Sine calibration, 45

Sine offset, 45

Spare part types, 7

Spare parts, 81

Spare parts catalog, 7

Sporadic fault, 8

Static electricity, 8

Status indicator, 35, 39

Supply unit KPS 600 LED indicators, 27

Supply voltage, 29, 30

T

Test data, 76

Toggle bit error, 26

Trace status, 73, 78

Transportation damage, 8

Trigger condition, 71

Trigger event, 72

Typical fault profiles, 9

U

Undervoltage, 30

Undervoltage/overvoltage, 8

Update display, 44

V

Version numbers, 43

W

Watchdog, 29

Z

Zoom function, 58

Index

Index -- iii

No results