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)
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 Elimination of fault:
-- 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 Elimination of fault:
-- Carry out BIOS update
System boots normally, display stays dark Possible causes:
-- KVGA defective
-- KCP2 connecting cable snapped
-- 24 V supply voltage for KCP2 not present in MFC3 Elimination of fault:
-- 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:
-- Defective motherboard Elimination of fault:
-- 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) Elimination of fault:
-- 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
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 Elimination of fault:
-- 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) Elimination of fault:
-- 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 Elimination of fault:
-- 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 Elimination of fault:
-- 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
Elimination of fault:
-- 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 Elimination of fault:
-- 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!)
Operating system crashes with exceptional error (blue screen) Possible causes:
-- Defective memory module(s) Elimination of fault:
-- Exchange memory module(s)
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
Elimination of fault:
-- 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 -- Defective memory module(s) Elimination of fault:
-- Reinstall control software -- Check settings in CMOS setup -- Exchange memory module(s)
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
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.
The following follow--up message is generated: “DSE axis assignment Ax, machine data loader canceled, erroneous %1 machine data”.
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.
The following follow--up message is generated: “DSE axis assignment Ax, machine data loader canceled, erroneous %1 machine data”.
Possible causes:
-- DSE incorrectly configured (jumper) -- DSE defective
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 -- PCI bus on motherboard faulty
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 com-mand 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
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 -- PCI bus on motherboard faulty
Elimination of fault:
-- 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
Elimination of fault:
-- 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
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 Elimination of fault:
-- 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 Elimination of fault:
-- Exchange MFC
3.6 Fault profiles related to the KCP
3.6.1 No display on the LCD Possible causes:
3.6.2 Drives cannot be switched on Possible causes:
3.6.3 No entries can be made via KCP Possible causes:
-- Connecting cable defective -- MFC defective (CAN bus) -- KCP defective
Elimination of fault:
-- Exchange connecting cable -- Exchange MFC
-- Exchange KCP
3.6.4 EMERGENCY STOP cannot be acknowledged Possible causes:
-- EMERGENCY STOP button defective -- Connecting cable defective
Elimination of fault:
-- Exchange KCP
-- Exchange connecting cable 3.6.5 Space Mouse does not work
Possible causes:
-- Connecting cable defective -- Space Mouse defective -- MFC defective (CAN bus) Elimination of fault:
-- Exchange connecting cable -- Exchange KCP
-- Exchange MFC
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 Elimination of fault:
-- 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 Elimination of fault:
-- Check configuration -- Exchange field bus card -- 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 Elimination of fault:
-- Exchange field bus card
3.7.4 The controller “hangs” after initialization of the field bus card Possible causes:
-- Field bus card defective Elimination of fault:
-- Exchange field bus card
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 Elimination of fault:
-- Exchange Interbus filter (if fiber--optic cable) -- Exchange Interbus card
4 Servo drive module messages and error displays
In the event of a drives error, messages are displayed in several ways.
4.1 Servo drive module LEDs (KSD1)
The operating state of the KSD is indicated by two LEDs on the front.
GN RD
Fig. 1 Servo drive module LED indicators
Red LED Green LED Meaning (message/fault)
Off Off No 24 V voltage
On Off Undefined drive servo state
Flashes quickly Flashing quickly (UIC > Ulimit) Fault present Flashes slowly Flashing slowly (UIC < Ulimit)
Flashing quickly (UIC > Ulimit)
Message is present (except in case of un-dervoltage UIC) [default value is 250 V]
Red LED Green LED Meaning (no message/fault)
Off Flashes slowly UIC < Ulimit
Off Flashes quickly UIC > Ulimit
Off On Servo enable, UIC > Ulimit
UIC: intermediate circuit voltage
Ulimit: intermediate circuit voltage = 250 V
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 Meaning/
cause of error Troubleshooting/
possible fault elimination DRIVES ERROR
Ax No.: TRIP KSD is in a fault state; robot carries
out Emergency Stop. See detailed error message which is also displayed.
OVERCURRENT
Ax 1. Overloading of the axis
2. I2t overload
Max. permissible number of commu-nication errors with the servo bus exceeded.
Too many consecutive toggle bit er-rors; cause short--circuit braking.
Check Interbus cable between DSE, KPS and KSDs.
HEAT SINK
TEMPERATURE Ax Overtemperature, heat sink 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 Check KSD/restart/exchange MOTOR CABLE Ax Power unit overcurrent
(short--circuit or ground fault), hardware monitoring
Ground fault, software monitoring
Check motor cable/motor
FAILURE OF
MOTOR PHASE Ax Motor phase failure Check motor cable/motor Drives error Ax
no.: 105 Checksum error in the control unit
device set Check KSD/restart/exchange
Drives error Ax
no.: 71 Microcontroller crash Check KSD/restart/exchange
Drives error Ax
no.: 79 Communication error with the
EEPROM in the control unit Check KSD/restart/exchange Drives error Ax
no.: 80 Communication error with the
EEPROM in the power unit Check KSD/restart/exchange Drives error Ax
no.: 106 Checksum error in the power unit
device set Check KSD/restart/exchange
5 KPS--600 messages and error displays
5.1 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
5.1.1 Meaning of LEDs 1 and 2
LED 1 (red) LED 2 (green) Priority* Meaning
OFF OFF Processor without power supply
OFF Flashes at 1.5 Hz Intermediate circuit voltage < 60 V
OFF ON Intermediate circuit voltage > 60 V
Flashes at 6 Hz OFF 1 Communication error
Flashes at 3 Hz OFF 2 Brake error
ON OFF 3 Main contactor K1 stuck
Flashes 5 times at 1.5 Hz
any 4 Error in BEA signal
(signal for flow of current through the ballast resistor)
Flashes 4 times at 1.5 Hz any 5 Ballast error
Flashes 3 times at 1.5 Hz any 6 Overvoltage in intermediate circuit
Flashes twice at 1.5 Hz any 7 Overtemperature in interior /
heat sink
Flashes once at 1.5 Hz any 8 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 Meaning of LEDs 3 and 4
LED 3 Meaning
Off Robot brakes not activated
On Robot brakes activated
LED 4 Meaning
Off External axis brakes not activated
On External axis brakes activated
5.1.3 Meaning of LEDs 5 and 6
Designation State of the red LED Meaning
V1 LED on General EMERGENCY STOP
activated
V2 LED on Local EMERGENCY STOP
activated
5.1.4 KPS--600 error messages on the KCP
Display in message window Meaning/cause of error Troubleshooting/
possible remedy Parameter error PMx
checksum Checksum error in
parameter set 1 Restart/exchange KPS
Parameter error PMx
Control Checksum error in the control
unit device set Restart/exchange KPS
Drives error PMx no.: 71 Microcontroller crash Restart/exchange KPS
Drives error PMx no.: 71 Microcontroller crash Restart/exchange KPS