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.
1.6List of error messages5..........................................................
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Error messages / troubleshooting
1Error 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
1.1Message 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.
1.2Message time
The message time indicates the time at which the message was generated.
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1.3Message number
With the aid of the message number, the corresponding cause, effect and remedy can quickly
be located in the list of error messages.
1.4Originator
The origin of the error is indicated in this field.
1.5Message text
The text of the error message is shown here.
1.6List 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:
1Error 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
1Message textEMERGENCY 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 textInternal error
Cause-- Internal KRL software test.
Monitor-- Within the KRL software.
Effect-- All active commands inhibited.
Remedy-- Acknowledge message.
3
Message textMESSAGE 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 textBUFFER 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 textMalfunction <HPU or RCP>
Cause-- KCP defective.
Monitor-- Cyclic.
Effect-- Ramp--down braking.
-- All active commands inhibited.
Remedy-- Replace KCP.
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1Error messages / troubleshooting (continued)
6Message textTransmission 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 textTPBASIS
Cause-- The point could not be created
8
Message textSystem 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 textMFC 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 textERROR DIGITAL OUTPUTS @P1@
Cause-- Short circuit at outputs 1--8 or 9--16.
Monitor-- Cyclic.
Effect-- Maximum braking.
Remedy--
Message textPROGRAM 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 textTOO 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
13Message textERROR 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 textSOFTPLC: @P1@
Cause--
Monitor--
Effect--
Remedy--
15
Message textOUTPUT MONITORING DC BUS VOLTAGE KPS: @P1@
Cause-- DC bus voltage of a KPS overloaded.
Monitor--
Effect--
Remedy--
16
Message textError 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 textWRONG/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
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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1Error messages / troubleshooting (continued)
19Message textFAILURE 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 textEXTERNAL 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 textSecond 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
100Message textRDW ** 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 textDSE ** 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 textENCODER CABLE FAILURE **
Cause-- Cable defective (e.g. loose connection).
-- RDW defective.
-- Encoder defective.
Monitor-- Cyclic.
Effect-- Maximum braking (dynamic braking).
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy-- Check encoder cable.
-- Check motor, resolver.
-- Possibly replace RDW.
103
Message textWATCHDOG INTERPOLATION CYCLE **
104
Cause-- DSE has not triggered software watchdog in the DP--RAM.
Monitor-- Cyclic.
Effect-- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy-- Replace DSE or MFC.
-- Software error.
Message textSYNCHRONIZATION 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 “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy-- Error in the DSE or PC area.
-- Software error.
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1Error messages / troubleshooting (continued)
105Message textTRANSMISSION ERROR DSE -- RDW **
Cause-- Open--circuit between RDW and DSE.
-- Transmission malfunctions.
Monitor-- Cyclic.
Effect-- Maximum braking.
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy-- Check shielding of encoder cable.
-- Check serial interface DSE--RDW.
106
Message textPERFORM 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 textEMERGENCY 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 textDYNAMIC 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 textCLEAR 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
110Message textADVANCED 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 textTEPRO INACTIVE
Cause-- SBC no longer sending a signal to KRC.
Monitor-- Cyclic.
Effect-- SBC interface inoperable.
Remedy-- Re--initialize SBC program.
112
Message textINVALID $TOOL: WORKING ENVELOPE SURVEILLANCE NOT
POSSIBLE
Cause-- “$TOOL” invalid when working envelope monitoring is activated.
Monitor-- Cyclic.
Effect-- None.
Remedy-- Assign “$TOOL” or switch off working envelope monitoring.
113
Message textRANGE 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 textWORKING 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 textDRIVE 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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1Error messages / troubleshooting (continued)
116Message textDSE WATCHDOG COMMAND **
Cause-- DSE has not executed a command.
Monitor
Effect-- Ramp--down braking.
Remedy-- Check hardware in the DSE, MFC area.
117
Message textTORQUE EXCEEDED AXIS @P1@
Cause
Monitor
Effect
Remedy
118
Message textHEAT 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 textMOTOR 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 textACKN. 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 textOVERCURRENT **
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 textBRAKE 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
MeldungstextUNDERVOLTAGE <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 textOVERVOLTAGE <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 texti2--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.
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 textMODE NOT ALLOWED
Cause-- E2 keyswitch in AUTO mode.
Monitor
Effect
Remedy
222
Message textPARITY 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 textPOWER 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 textPOWER 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 textMOTOR CABLE **
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Cause--
Monitor--
Effect--
Remedy--
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1Error messages / troubleshooting (continued)
226Message textFAILURE OF HEAT SINK TEMPERATURE SENSOR **
Cause--
Monitor--
Effect--
Remedy--
227
Message textFAILURE OF CABINET INTERIOR TEMPERATURE SENSOR <AXIS
NUMBER>
Cause--
Monitor--
Effect--
Remedy--
228
Message textDRIVES PARAMETER DATA ** INVALID
Cause--
Monitor--
Effect--
Remedy--
229
Message textFAILURE OF MOTOR TEMPERATURE SENSOR <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 $ADAR_AXIS
without connecting ADAR interfaces.
Monitor-- At “Power on”.
-- After editing the machine data.
-- After loading the machine data.
Effect-- No RC ready.
Remedy-- Correct the machine datum.
254
Message textDSE FILE <program name> NOT AV AILABLE
Cause-- The DSE program entered in the RD_HWINF.INI file does not exist.
Monitor
Effect
Remedy-- Enter or alter the DSE program.
255
Message text<$ 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 textCHECK 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.
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Error messages / troubleshooting
257Message textERRONEOUS 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 textERRONEOUS 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 textUSER 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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1Error messages / troubleshooting (continued)
261Message textOPTION 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 textERRONEOUS <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 textERRONEOUS 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 textRDW 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.