SOFTWARE
KR C...
Error messages / troubleshooting
KUKA System Software (KSS)
Issued: 10.Oct.2004 Version: 01
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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not bereproduced 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.
PD Interleaf
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Contents
1 Error messages / troubleshooting 4.................................
1.1 Message groups 4...............................................................
1.2 Message time 4.................................................................
1.3 Message number 5..............................................................
1.4 Originator 5.....................................................................
1.5 Message text 5..................................................................
1.6 List of error messages 5..........................................................
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Error messages / troubleshooting
1 Error messages / troubleshooting
Messages of all categories are displayed in the message window. These can be either
informative messages that do not need to be acknowledged or messages that have to be
acknowledged.
A message consists of the following items of information, for example:
Message group
Message time
Message number
Originator
Message text
COMMAND ACCELERATION EXCEEDED A2
ACTIVE COMMANDS INHIBITED
1.1 Message groups
Hint messages
provide the operator with explanatory information, for example, if an illegal key has been
pressed.
Operational messages
signal the status of the system that has led to a control reaction, e.g. Emergency Stop. The
message is cleared once its cause has been eliminated. In some cases, a secondary signal
that has to be acknowledged is set for reasons of safety.
Acknowledgement messages
indicate a situation that must in all instances be recognized and acknowledged with the
acknowledge key. They are often a consequence of a status (operational) message. An
acknowledgement message stops a movement or prevents further operation.
Dialog messages
require confirmation by the operator (“Yes” or “No” softkeys). The message is cleared after
it has been confirmed.
1.2 Message time
The message time indicates the time at which the message was generated.
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1.3 Message number
With the aid of the message number, the corresponding cause, effect and remedy can quickly
be located in the list of error messages.
1.4 Originator
The origin of the error is indicated in this field.
1.5 Message text
The text of the error message is shown here.
1.6 List of error messages
To make it easier to find error messages in the following list, the message number is shown
first, unlike on the display. By referring to this message number, it is possible to obtain further
information on an error and the appropriate remedial action. This information is subdivided
into:
1 Error messages / troubleshooting (continued)
Message text
is the actual text of the error message as displayed.
Cause
gives a detailed description of the cause of the error.
Monitor
indicates when the conditions for generation of the message are checked.
Effect
describes how the controller reacts to the error.
Remedy
describes what action the user can take to eliminate the error.
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Error messages / troubleshooting
1 Message text EMERGENCY STOP
Cause -- Emergency Stop pushbutton pressed.
-- Emergency Stop initiated by the software.
Monitor -- Cyclic.
Effect -- Path--maintaining stop.
-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton and Emergency Stop circuit.
-- Release the Emergency Stop pushbutton.
-- Rectify and acknowledge the signalled fault.
2
Message text Internal error
Cause -- Internal KRL software test.
Monitor -- Within the KRL software.
Effect -- All active commands inhibited.
Remedy -- Acknowledge message.
3
Message text MESSAGE BUFFER OVERFLOW
Cause -- The message buffer, which contains the currently active messages
(acknowledgement and status messages), is full up to a specific limit.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Rectify and acknowledge the signalled faults.
4
Message text BUFFER BATTERY VOLTAGE LOW xx
Cause -- Voltage of the backup battery too low.
Monitor -- At “Power off”.
-- Cyclic.
Effect -- The battery voltage is checked when the power is switched off. When
the message is displayed, it is necessary to wait until the battery has
recharged. Only then may the controller be switched off.
-- Cyclic --> none.
Remedy -- Change the battery.
-- After the battery has been charged, the message “Ackn. batt. voltage”
is displayed --> acknowledge.
5
Message text Malfunction <HPU or RCP>
Cause -- KCP defective.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Replace KCP.
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1 Error messages / troubleshooting (continued)
6 Message text Transmission error <HPU or RCP>
Cause -- Fault in KCP connection.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the KCP cable.
7
Message text TPBASIS
Cause -- The point could not be created
8
Message text System time invalid
Cause -- The system time is invalid after TIME_HW_FAILURE and has been
set to the initial value.
Monitor -- When the controller is booted.
Effect -- The system time is initialized with 01.01.93 00:00:00,00.
Remedy -- Update the system time with the form “systime”.
9
Message text MFC overtemperature
10
11
12
Cause -- The temperature sensor on the MFC has been triggered.
Monitor -- Cyclic.
Effect -- Path--maintaining braking.
Remedy -- Check fan. Exchange MFC if necessary.
Message text ERROR DIGITAL OUTPUTS @P1@
Cause -- Short circuit at outputs 1--8 or 9--16.
Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy --
Message text PROGRAM STACK OVERFLOW
Cause -- KRL program contains too many nested structures or too many recur-
sive subprogram calls! The C--stack of the R--INT would otherwise
overflow.
Monitor -- In program processing.
Effect -- Ramp--down braking.
Remedy -- Change the structure of the program.
Message text TOO MANY MESSAGES
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Cause -- Too many messages have been cyclically generated.
Monitor -- When a message is generated.
Effect -- All active commands are cancelled and cannot be restarted.
Remedy -- The KRC has to be booted.
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Error messages / troubleshooting
13 Message text ERROR SAFETY LOOP
Cause -- A channel has failed or more than one enabling switch has been
pressed.
Monitor -- Cyclic.
Effect -- Path--maintaining braking, active commands inhibited.
Remedy --
14
Message text SOFTPLC: @P1@
Cause --
Monitor --
Effect --
Remedy --
15
Message text OUTPUT MONITORING DC BUS VOLTAGE KPS: @P1@
Cause -- DC bus voltage of a KPS overloaded.
Monitor --
Effect --
Remedy --
16
Message text Error while reading “O file”
17
18
Cause -- Error during loading/reading of “ident_vx.o”: memory or file not found.
Monitor -- In the write function “w_ident_state”.
Effect -- Jump to the end in load data program.
Remedy -- Copy the file “ident_vx.o” to the directory “/ir_spec/l_ident”,
or increase memory by changing the value “VxWinRAM” in the registry.
Message text WRONG/UNKNOWN HARDWARE FOUND
Cause -- During setup, the wrong control hardware (KR C1, KR C1A, KR C2)
was selected or the hardware configuration is invalid.
Monitor --
Effect -- The controller is inoperable.
-- Robot traversing not possible.
Remedy -- Carry out setup again or make appropriate changes to
hardware configuration.
Message text Servobus DSE--No. %1 participant No. %2 unknown
Cause -- An unknown device which cannot be supported has been inserted in
Interbus
Monitor -- DSE ID, device ID
Effect -- The robot can no longer be traversed
Remedy -- Remove unknown device from servo bus
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1 Error messages / troubleshooting (continued)
19 Message text FAILURE OF MOTOR PHASE <axis>
Cause -- Power module, intermediate circuit voltage discharged.
Monitor -- Cyclic.
Effect -- Dynamic braking.
-- All active commands inhibited.
Remedy -- Switch on drives.
-- Check power module, DSE.
20
Message text EXTERNAL EMERGENCY STOP PRESSED
Cause -- Emergency Stop button pressed.
-- Emergency braking triggered by software.
Monitor -- Cyclic.
Effect -- Path--maintaining braking.
-- All active commands inhibited.
Remedy -- Check the Emergency Stop pushbutton.
-- Rectify and acknowledge the signalled fault.
21
Message text Second motorcable not connected
Cause -- Second motor cable is not connected or is incorrectly connected; the
additional cable contains two wires which are connected to the robot;
the return signal is connected to the KPS X114, pin 7
Monitor -- Cyclic.
Effect -- The robot cannot be traversed
Remedy -- Check second motor cable and return signal at KPS X114, pin 7
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Error messages / troubleshooting
100 Message text RDW ** BOOT UP FAILURE
Cause -- The resolver/digital converter (RDW) could not be initialized when
the controller was booted.
Monitor -- At runup.
Effect --
Remedy -- Replace RDW, DSE or cable between RDW and DSE.
101
Message text DSE ** BOOT UP FAILURE
Cause -- The DSE could not be initialized when the controller was booted.
Monitor -- At runup.
Effect -- Maximum braking (dynamic braking).
Remedy -- Replace DSE, MFC or motherboard.
102
Message text ENCODER CABLE FAILURE **
Cause -- Cable defective (e.g. loose connection).
-- RDW defective.
-- Encoder defective.
Monitor -- Cyclic.
Effect -- Maximum braking (dynamic braking).
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check encoder cable.
-- Check motor, resolver.
-- Possibly replace RDW.
103
Message text WATCHDOG INTERPOLATION CYCLE **
104
Cause -- DSE has not triggered software watchdog in the DP--RAM.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Replace DSE or MFC.
-- Software error.
Message text SYNCHRONIZATION ERROR WITH DSE **
Cause -- DSE has not received feed command value for 1 interpolation cycle
although servo--control is active.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Error in the DSE or PC area.
-- Software error.
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1 Error messages / troubleshooting (continued)
105 Message text TRANSMISSION ERROR DSE -- RDW **
Cause -- Open--circuit between RDW and DSE.
-- Transmission malfunctions.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.
106
Message text PERFORM MASTERING ** !
Cause -- Position actual value difference after restart too great and sensor
mastering not possible because sensor location run has not been
performed.
Monitor -- At “Power on”.
-- During mastering.
Effect -- All active commands inhibited.
Remedy -- Perform mastering.
107
Message text EMERGENCY STOP DUE TO DIAL ADJUSTMENT
108
109
Cause -- Softkeys for dial adjustment pressed.
-- Value assignment “$TURN = 1”.
-- Encoder setting, absolute or incremental.
Monitor -- When “$TURN” instruction is executed.
Effect -- Dynamic braking.
-- 0 signal at “$ALARM_STOP” output
-- All active commands inhibited.
Remedy -- Leave the mastering menu by pressing the Recall key twice.
Message text DYNAMIC BRAKING ACTIVE
Cause -- If the controller detects a request for maximum (dynamic) braking, it
geneates the status (operational) message “DYNAMIC BRAKING
ACTIVE”, which remains active until all axies have stopped.
Monitor -- Cyclic.
Remedy -- The status message “DYNAMIC BRAKING ACTIVE” is reset by the
controller when the robot is at standstill without a secondary message
being generated.
Message text CLEAR FAST MEASURING INPUT @P1@
Cause -- Rapid gauging has been switched on.
Monitor -- During rapid gauging.
Effect -- Rapid gauging becomes active when measuring tool has been
moved free.
Remedy -- Move measuring tool free.
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Error messages / troubleshooting
110 Message text ADVANCED PATH PROFILE NOT POSSIBLE WITH LINKED EXTER-
NAL AXES
Cause -- Coupling of external axes in higher motion profile.
Monitor -- During command and program execution.
Effect --
Remedy --
111
Message text TEPRO INACTIVE
Cause -- SBC no longer sending a signal to KRC.
Monitor -- Cyclic.
Effect -- SBC interface inoperable.
Remedy -- Re--initialize SBC program.
112
Message text INVALID $TOOL: WORKING ENVELOPE SURVEILLANCE NOT
POSSIBLE
Cause -- “$TOOL” invalid when working envelope monitoring is activated.
Monitor -- Cyclic.
Effect -- None.
Remedy -- Assign “$TOOL” or switch off working envelope monitoring.
113
Message text RANGE OVERFLOW ** **
114
115
Cause -- Overflow of the actual value of an endless axis: actual value > +/--
90*10E15 increments or --99999000 < $REVO_NUM < 999999000
Monitor -- Cyclic in the interpolation cycle.
Effect -- Path--maintaining Emergency Stop.
Remedy -- Turn back or remaster the axis concerned.
Message text WORKING ENVELOPE NO. @P1@ VIOLATED
Cause -- TCP is inside a working envelope with MODE INSIDE STOP or outside
a working envelope with MODE OUTSIDE STOP.
Monitor -- Cyclic.
Effect -- Path--maintaining braking;
-- All active commands inhibited.
Remedy -- Switch off working envelope or use key on the KCP to override work
envelope monitoring, move free in T1 mode.
Message text DRIVE FREE WORK ENVELOPE %1
Cause -- TCP is inside a working envelope with
MODE INSIDE STOP or outside a working envelope with MODE
OUTSIDE STOP and the working envelope monitoring is overridden.
Monitor -- Cyclic.
Effect --
Remedy -- Free work envelope.
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1 Error messages / troubleshooting (continued)
116 Message text DSE WATCHDOG COMMAND **
Cause -- DSE has not executed a command.
Monitor
Effect -- Ramp--down braking.
Remedy -- Check hardware in the DSE, MFC area.
117
Message text TORQUE EXCEEDED AXIS @P1@
Cause
Monitor
Effect
Remedy
118
Message text HEAT SINK TEMPERATURE **
Cause -- Thermostatic switch on the heat sinks of the servo output stage is
tripped due to overheating of the output stage transistors.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Clean the heat sinks.
119
Message text MOTOR TEMPERATURE **
120
121
Cause -- PTC thermistor (measuring shunt) in the motor winding has been
tripped (motor temperature too high).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Program more movement breaks.
Message text ACKN. MOTOR BLOCKED **
Cause -- As soon as the torque command value supplied by the speed controller
exceeds 30% of the max. torque command value, integration is
started, and when the value of i*t reaches approx. 0.75 [(torque
command value / max. torque command value) * sec] the control is
switched off (i*t -- monitoring).
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
-- Check that the axis is moving freely.
Message text OVERCURRENT **
Cause -- The current of each axis is monitored and the amplifier--internal current
protection is tripped if the power consumption is too high.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
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Error messages / troubleshooting
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
122
Message text BRAKE FAULT **
Cause -- The brake cable is monitored for short--circuit, overload and cable
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
123
Meldungstext UNDERVOLTAGE <axis number>
Cause -- The internal operating voltage (+15V) of the servo output stage is
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
124
Message text OVERVOLTAGE <power module number>
KCP.
break.
-- With the PM6, all axes are supplied from one brake driver.
KCP.
monitored. Undervoltage results in power failure.
KCP.
125
126
127
Cause -- The intermediate--circuit voltage is too high. Possible causes are a de-
fective ballast (feedback) resistor or ballast fuse, a defective power
module, brake ramp too steep etc.
Monitor -- Cyclic.
Effect -- Ramp--down braking. Program processing stopped.
Remedy -- Eliminate the fault and reset it by pressing the acknowledge key on the
KCP.
Message text i2--t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string1> AFTER <string2> s EXCEEDED 100%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
Message text REGULATOR LIMIT EXCEEDED <axis number>
Cause -- Following error too great. The axis does not follow the command value.
Monitor -- Cyclic in the position controller.
Effect -- Maximum braking.
Remedy -- Check the axis.
Message text <axis number> DETACHED EXTERNAL AXIS
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Cause -- Auxiliary (external) axis is operated as an asynchronous axis.
Monitor -- Cyclic.
Effect
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129
130
1 Error messages / troubleshooting (continued)
Remedy
Message text SOFTWARE LIMIT SWITCH OF DETACHED EXTERNAL AXIS
<motion direction> <axis number>
Cause -- Asynchronous axis has tripped the pos. or neg. software limit
switch.
Monitor -- The software limit switch is checked cyclically if the axis is operated
as an asynchronous axis.
Effect
Remedy
Message text i2--t MONITORING, CURRENT LIMIT OF THE MOTOR CABLE
<string1> AFTER <string2> s EXCEEDED 95%
Cause -- Axis overloaded. The value for the maximum permissible limit current
is specified in the machine data by “$CURR_MON[]”.
Monitor -- Cyclic.
Effect -- Ramp--down braking, active commands inhibited.
Remedy -- Reduce load.
Message text K1 CONTACT FAIL TO OPEN <KPS number>
131
132
133
Cause -- The K1 contact is welded.
Monitor --
Effect -- The energy supply system is not interrupted.
Remedy -- Exchange contactor, KPS.
Message text BUS VOLTAGE CHARGING UNIT IS DEFECTIVE <KPS number>
Cause -- The optocoupler on the KPS is not registering current flow.
Monitor --
Effect -- Intermediate circuit cannot be loaded.
Remedy -- Exchange KPS.
Message text BRAKE DEFECTIVE <axis ...>
Cause -- Wear on brakes, defective brake.
Monitor --
Effect -- Axis moves in an uncontrolled manner.
Remedy -- Exchange motor.
Message text MONITORING OF THE ACTUAL VELOCITY @P1@
Cause -- Fault in control loop:
-- motor cables of two axes interchanged;
-- error in the axis assignment;
-- power module defective;
-- resolver unmastered.
Monitor -- Cyclic.
Effect -- Robot remains motionless.
Remedy -- Rectify the corresponding error in the control loop.
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Error messages / troubleshooting
134 Message text DN CH ... WRONG FASTWRITE MACID IN INI FILE
Cause --
Monitor --
Effect --
Remedy --
135
Message text DN CH ... MODULE ERROR ...
Cause --
Monitor --
Effect --
Remedy --
136
Message text DN CH ... SLAVE ERROR ...
Cause --
Monitor --
Effect --
Remedy -- Exchange contactor, KPS.
137
Message text DN CH ... FIRMWARE ERROR
138
139
140
Cause --
Monitor --
Effect --
Remedy --
Message text DN CH ... HARDWARE ERROR
Cause --
Monitor --
Effect --
Remedy -- Exchange contactor, KPS.
Message text DN CH ... BUS ERROR ...
Cause --
Monitor --
Effect --
Remedy --
Message text DN CH ... WATCHDOG ERROR
Cause --
Monitor --
Effect --
Remedy --
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1 Error messages / troubleshooting (continued)
141 Message text DN CH ... USER ERROR ...
Cause --
Monitor --
Effect --
Remedy --
142
Message text DN CH ... CONFIGURATION MODE ENABLED
Cause --
Monitor --
Effect --
Remedy --
143
Message text Ixtservodrive%1exceedvalue%2%%
Cause -- If the defined Ixt monitoring warning value of a drive servo is exceeded,
the robot must be brought to a standstill; otherwise, the drive servo is
deactivated when the maximum value of 100% is exceeded
Monitor -- Cyclic, the warning bit on the drive servo
Effect -- The robot is stopped in a controlled manner.
Remedy -- Verify load data
-- If necessary, reduce the load cycle (wait time)
-- Use stronger robot
146
147
Message text Wrong amplifier %1
Cause -- Drive module of a slave axis does not correspond to drive module on
the associated master axis
Monitor -- Cyclic.
Effect -- Traversing not possible
Remedy -- Shut down controller, exchange drive module for one corresponding to
the master axis and reboot controller
Message text DRIVE FREE AXIS WORK ENVELOPE NO. %1
Cause -- The robot is inside a working envelope with MODE INSIDE STOP or
outside a working envelope with MODE INSIDE STOP and the working
envelope monitoring is overridden.
Monitor -- Cyclic.
Effect --
Remedy -- Free axis work envelope
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Error messages / troubleshooting
148 Message text Axis work envelope No. %1 violated
Cause -- The robot is inside a working envelope with MODE INSIDE STOP or
outside a working envelope with MODE OUTSIDE STOP
Monitor -- Cyclic.
Effect -- Path--maintaining braking, all active commands inhibited
Remedy -- Switch off axis working envelope or override work envelope monitoring
in T1 mode and move free
155
200
201
202
Message text <axis> DECOUPLED AUXILIARY AXIS
Cause --
Monitor --
Effect --
Remedy --
Message text DRIVES CONTACTOR OFF
Cause -- Power module, intermediate--circuit voltage discharged.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Switch drives on.
-- Check power module, check DSE.
-- Emergency Stop is active, drives circuit is interrupted.
Message text KCP DEADMAN SWITCH
Cause -- The safety (deadman) switch has been released during an active
function (motion of an axis) in mode T1 or T2.
Monitor -- Cyclic.
Effect -- Maximum braking.
-- All active commands inhibited.
Remedy -- Press safety switch.
-- Check KCP, safety logic.
Message text I/O RECONFIGURATION
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Cause -- An I/O reload command has been transmitted via the KCP.
Monitor --
Effect -- Path--maintaining braking.
Remedy -- After successful reconfiguration, the normal operating state is
automatically restored.
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1 Error messages / troubleshooting (continued)
203 Message text GENERAL MOTION ENABLE
Cause -- Low signal at $MOVE_ENABLE input.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check the input.
204
Message text HARDWARE LIMIT SWITCH / +24V MISSING
Cause -- The hardware limit switch has been tripped.
Monitor -- Cyclic.
Effect -- Maximum braking.
Remedy -- Shunt out the hardware limit switch and move axis off limit switch.
205
Message text SOFTWARE LIMIT SWITCH <motion direction> <axis number>
Cause -- The software limit switch of the axis indicated has been tripped in the
direction indicated. (The message is effective only after “Robot
synchronized”).
Monitor -- Cyclic.
Effect -- Maximum braking.
-- Movement in the direction indicated is inhibited.
Remedy -- Move the axis in the opposite direction (no change to the robot--specific
coordinate system takes place).
206
Message text SERVO PARAMETERS <axis> LINE <integer> INCORRECT
207
208
Cause -- The parameters in the servo file are incorrect.
Monitor -- While loading machine data.
Effect --
Remedy -- Correct the parameters.
Message text OPERATOR SAFETY / GATE OPEN
Cause -- Operator safety has been tripped in the AUTOMA TIC or EXTERNAL
mode (input at the peripheral interface).
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Switch to mode T1 or T2 (in these modes the robot can be moved
when the signal is low).
-- Close the safety gate.
-- Check the input.
Message text FAILURE IN ESC SAFETY LOOP
Cause -- Emergency Stop button pressed.
-- Emergency braking triggered by software.
Monitor -- Cyclic.
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Error messages / troubleshooting
Effect -- Path--maintaining braking.
Remedy -- Check the Emergency Stop pushbutton;
209
Message text PASSIVE STOP <RCP or teach pendant>
Cause -- Stop from a passive operator control unit (the message is displayed
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Acknowledge the message “Passive Stop”.
210
Message text STOP KEY <RCP or teach pendant>
Cause -- The start key or a traversing key has been actuated while the stop
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Check the stop key.
211
Message text CHECK SAFETY LOGIC. DRIVES OFF TIMEOUT DURING EMER-
Cause --
Monitor --
Effect --
Remedy --
212
Message text ERROR WRITING TO PERCEPTRON
-- All active commands inhibited.
-- Rectify and acknowledge the signalled fault.
only if an active process has been stopped).
-- All active commands inhibited.
key is depressed.
-- All active commands inhibited.
GENCY STOP OCCURRED
--
213
214
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Cause --
Monitor --
Effect --
--
Remedy --
Message text ERROR WRITING TO BOSCH
Cause --
Monitor --
Effect --
--
Remedy --
Message text COMMON DRIVES ERROR <axis number>
Cause --
Monitor --
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216
217
1 Error messages / troubleshooting (continued)
Effect --
--
Remedy --
Message text COMMON DRIVES ERROR <axis number>
Cause --
Monitor --
Effect --
--
Remedy --
Message text DRIVES ERROR ... NO.: ...
Cause -- The Start key or a direction key was activated while the Stop key
was pressed.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
-- All active commands inhibited.
Remedy -- Check Stop key.
Message text EMERGENCY STOP FROM KRC ( ALARM STOP )
218
219
Cause -- An alarm stop has been initiated by the KRL system software;
another serious error has occurred.
Monitor -- Cyclic.
Effect -- Maximum braking. All active commands inhibited.
Remedy -- Eliminate and acknowledge the signalled fault (serious error).
Message text FEEDBACK SWITCH TOO LONG ON **
Cause -- The energy of the axis to be braked was too high.
Monitor
Effect -- Ramp--down braking.
Remedy -- Power module ballast (feedback) switch defective.
-- Brake ramp in the program too steep.
Message text CABINET TEMPERATURE TOO HIGH **
Cause -- The cabinet temperature has risen above the permissible limit value.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Reduce the external temperature.
-- Change the site of installation.
-- Check the fans.
-- Clean the heat exchanger.
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Error messages / troubleshooting
220 Message text DRIVES CONTACTOR OFF, INTERMEDIATE CIRCUIT LOADED !!!
Cause -- The drives contactor drops out. The energy in the intermediate circuit
is sufficient to ensure a path--maintaining stop. Caution: the
intermediate circuit is still charged! The intermediate circuit is
discharged after about 2 minutes. The message “DRIVES NOT
READY” is then displayed.
Monitor -- Cyclic.
Effect -- Path--maintaining Emergency Stop
Remedy -- Switch drives on again.
-- Check drives circuit for faults.
221
Message text MODE NOT ALLOWED
Cause -- E2 keyswitch in AUTO mode.
Monitor
Effect
Remedy
222
Message text PARITY ERROR POWERMODULE **
223
224
225
Cause -- A parity error has occurred more than five times in succession when
reading the power module register.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Too much interference at the power module interface, or power module
defective. Check cable, check shielding, replace power module.
Message text POWER MODULE AXIS ** NOT OR WRONGLY PLUGGED
Cause -- The axis is incorrectly plugged into the power module or not connected
at all.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Connect the axis correctly (high or low power).
Message text POWER FAIL
Cause -- The cabinet voltage has been switched off, the mains voltage is
interrupted.
Monitor
Effect -- Path--maintaining Emergency Stop, buffering of the mastering data,
saving all data on HDD.
Remedy -- Check the mains voltage.
Message text MOTOR CABLE **
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Cause --
Monitor --
Effect --
Remedy --
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1 Error messages / troubleshooting (continued)
226 Message text FAILURE OF HEAT SINK TEMPERATURE SENSOR **
Cause --
Monitor --
Effect --
Remedy --
227
Message text FAILURE OF CABINET INTERIOR TEMPERATURE SENSOR <AXIS
NUMBER>
Cause --
Monitor --
Effect --
Remedy --
228
Message text DRIVES PARAMETER DATA ** INVALID
Cause --
Monitor --
Effect --
Remedy --
229
Message text FAILURE OF MOTOR TEMPERATURE SENSOR <AXIS NUMBER>
230
231
232
Cause --
Monitor --
Effect --
Remedy --
Message text WRONG DRIVES PARAMETER <AXIS NUMBER> **
Cause --
Monitor --
Effect --
Remedy --
Message text ERROR SYNC. INPUT DRIVE <AXIS>
Cause --
Monitor --
Effect --
Remedy --
Message text SYNCHRONISATION ERROR DRIVE <AXIS>
Cause --
Monitor --
Effect --
Remedy --
Fehlermeldungen 09.02.01 en
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Error messages / troubleshooting
233 Message text <AXIS> WITHOUT PO WER
Cause --
Monitor --
Effect --
Remedy --
234
Message text COMMON DRIVES ERROR <AXIS NUMBER>
Cause --
Monitor --
Effect --
Remedy --
235
Message text COMMON DRIVES ERROR <AXIS NUMBER>
Cause --
Monitor --
Effect --
Remedy --
236
Message text COMMON DRIVES ERROR <AXIS NUMBER>
237
238
239
Cause --
Monitor --
Effect --
Remedy --
Message text COMMON DRIVES ERROR <AXIS NUMBER>
Cause --
Monitor --
Effect --
Remedy --
Message text COMMON DRIVES ERROR <AXIS NUMBER>
Cause --
Monitor --
Effect --
Remedy --
Message text LOADING ** SERVO PARAMETERS **
Cause -- Loading drive servo parameters
Monitor --
Effect --
Remedy --
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1 Error messages / troubleshooting (continued)
240 Message text PLEASE SWITCH OFF THE CABINET
Cause -- The drive servo parameters have been loaded, but will not take effect
until the next reboot.
Monitor --
Effect --
Remedy --
241
Message text SERVOFILE CONFIGURATION ** DOES NOT FIT THE ** RELEASE
**
Cause -- The servo file configuration contains parameters for the drive servos
which are not supported by the firmware.
Monitor --
Effect --
Remedy -- Upgrade drive servo firmware or servo files.
242
Message text ** FIRMWARE RELEASE **
Cause -- Information about the firmware release of the axis in question.
Monitor --
Effect --
Remedy -- Upgrade drive servo firmware or servo files.
243
Message text SOFTWARE OF DSE ** DOES NOT FIT THE HARDWARE OR
DEFECTIVE DSE
Cause -- The wrong software was configured for the DSE
DSEAT and KR C1A/KR C2.
Monitor --
Effect --
Remedy -- Configure the correct software.
244
Message text ** SOFTWARE VERSION INCORRECT
245
246
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Cause -- DSE software and kernel system do not work together.
Monitor --
Effect --
Remedy -- Configure the correct DSE software.
Message text SERVO BUS DISTURBANCE DSE **
Cause -- Defective bus cable.
Defective bus module.
Defective bus driver.
Monitor -- Rectify fault.
Effect --
Remedy --
Message text SERVO BUS DISTURBANCE DSE **, NO BUFFERING AND
AUTOMATIC DATA STORAGE POSSIBLE
Cause -- Buffering is activated via the servo bus on the KPS. If communication
with the KPS is faulty, the buffering cannot be activated and switch--off
takes place immediately.
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Error messages / troubleshooting
Monitor --
Effect --
Remedy -- Re--establish communication with the KPS.
247
Message text SERVO BUS DISTURBANCE **
Cause --
Monitor --
Effect --
Remedy --
248
Message text SERVO BUS DISTURBANCE **
Cause --
Monitor --
Effect --
Remedy --
249
Message text $MOVE_ENABLE INPUT (1025) NOT ALLOWED
250
251
252
Cause --
Monitor --
Effect --
Remedy --
Message text INCORRECT SERVO PARAMETER <AXIS>
Cause --
Monitor --
Effect --
Remedy --
Message text <variable> OVERLAPPING OUTPUT SIGNALS
Cause -- Interface unit outputs assigned twice.
Monitor -- At “Power On”.
After editing the machine data.
After loading the machine data.
Effect -- No RC Ready.
Remedy -- Value assignment.
Message text <variable> INTERFACE--I/O ASSIGNMENT ERROR <correct index>
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Cause -- Double assignment of interface controller output.
Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the indicated machine datum.
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1 Error messages / troubleshooting (continued)
253 Message text ERRONEOUS DSE AXIS ASSIGNMENT <axis number>
Cause -- Machine datum $IFACE_DRV[6] has been assigned twice to a drive
interface, or a non--existent interface has been addressed.
-- KTL encoders have been entered in IFACE_DRV[6] without connecting APC interfaces, or ADAR axes have been entered in $ADAR_AXIS
without connecting ADAR interfaces.
Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the machine datum.
254
Message text DSE FILE <program name> NOT AV AILABLE
Cause -- The DSE program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter or alter the DSE program.
255
Message text <$ variable> INVALID VALUE
256
Cause -- The machine data loader has detected that a variable contains an
incorrect value:
a) Limit monitoring tripped.
b) Machine data not logically coherent.
Monitor -- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct the value assignment.
Message text CHECK MACHINE DATA !
Cause -- It cannot be assured that the machine data loaded during a cold
start are valid for the connected robot.
Monitor -- Generated at cold start.
Effect -- No RC ready.
-- Controller is in its initial state, i.e. tasks dependent on machine data
are not generated.
Remedy -- Either edit or copy the machine data or option data file.
Fehlermeldungen 09.02.01 en
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Error messages / troubleshooting
257 Message text ERRONEOUS USER DATA
Cause -- The user data loader has detected that a variable contains an incorrect
value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the user data.
-- After loading the user data (DEFDAT $CUSTOM PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
258
Message text ERRONEOUS OPTION DATA
Cause -- The option data loader has detected that a variable contains an incor-
rect value:
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the option data.
-- After loading the option data (DEFDAT $OPTION PUBLIC).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
259
Message text ** MACHINE DATA LOADER ABORTED
260
Cause -- The errors detected by the machine data loader exceed the capacity
of the message buffer.
Monitor -- At “POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
Message text USER DATA LOADER ABORTED
Cause -- The errors detected by the user data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the user data.
-- After loading the user data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
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1 Error messages / troubleshooting (continued)
261 Message text OPTION DATA LOADER ABORTED
Cause -- The errors detected by the option data loader exceed the capacity of
the message buffer.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the option data.
-- After loading the option data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
262
Message text ERRONEOUS <path> MACHINE DATA
Cause -- The machine data loader has detected a variable with an illegal value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- At “POWER ON”.
-- After editing the machine data.
-- After loading the machine data.
Effect -- No RC ready.
263
Message text ERRONEOUS CORRECTION DATA
264
265
Cause -- The correction data loader has detected a variable with an illegal value.
a) Limit monitoring tripped.
b) Data not logically coherent.
Monitor -- POWER ON after editing the correction data, after loading the
correction data (DEFDAT $ROBCOR).
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
Message text <path> CORRECTION DATA LOADER ABORTED
Cause -- The errors detected by the correction data loader exceed the capacity
of the message buffer.
Monitor -- At “POWER ON”.
-- After editing the correction data.
-- After loading the correction data.
Effect -- No RC ready.
Remedy -- Correct value assignment of the indicated variable.
Message text RDW FILE <program name> NOT AV AILABLE
Cause -- The RDW program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy -- Enter the RDW program correctly in the INI file.
Fehlermeldungen 09.02.01 en
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Error messages / troubleshooting
266 Message text OVERTEMPERATURE FEEDBACK RESISTOR <power module no.>
OR FAN
Cause -- The ballast (feedback) resistor has overheated. In the motion program
the robot is cyclically accelerated and decelerated without a break.
Monitor -- Cyclic.
Effect -- Ramp--down braking.
Remedy -- Insert wait times into the program, reduce the acceleration.
267
Message text WATCHDOG POWER MODULE <power module number>
Cause -- The watchdog on the power module has dropped out. The watchdog
is triggered by the DSE every 0.125ms.
Monitor -- Cyclic.
Effect -- Dynamic braking.
Remedy -- Troubleshooting in the DSE and power module area.
268
Message text MEMORY TEST ERROR DSE <DSE number 1 --4>
Cause -- The memory test on the DP--RAM of the DSE detected an error.
Monitor -- Runup.
Effect -- Active commands inhibited.
Remedy -- Replace DSE or MFC.
269
Message text DSE <DSE number 1--4> NOT AVAILABLE
270
271
Cause -- The bit on the MFC indicating whether a DSE is inserted is not set
although axes are allocated to this DSE.
Monitor -- At runup.
Effect -- Active commands inhibited.
Remedy -- Insert DSE, replace MFC or DSE.
Message text INCORRECT POWER MODULE SETTING <axis>
Cause -- Double assignment of $PMCHANNEL or incorrect channel.
Monitor -- When loading the robot machine data.
Effect -- Machine data loader aborted.
Remedy -- Correct $PMCHANNEL.
Message text ROBOT NO. ** DOES NOT CORRESPOND TO CALIBRATION FILE
**
Cause --
Monitor --
Effect --
Remedy --
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Fehlermeldungen 09.02.01 en
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