KRC 2 Operating Manual

CONTROL CABINET
KR C2
Operating Handbook
Fault Analysis
Issued: 20 Mar 2004 Version: 00
Fehler–HBKRC2 02.04.00 en
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e Copyright KUKA Roboter GmbH
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.
PD Interleaf
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Contents
1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Procurement of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Procedure for fault analysis and elimination . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Exact analysis of the fault profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Comparison with typical fault profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Isolation of faults by exchanging components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Set analysis settings to output state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Final function tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Servo drive module messages and error displays . . . . . . . . . . . . . . . . . . 9

3.1 Servo drive module LEDs (KSD1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 KCP messages for drives diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 KPS–600 messages and error displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1 Supply unit KPS–600/10 and /20 LED indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.1 States of the two top LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.2 States of the middle and lower green LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.3 States of the middle and lower red LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.4 KPS–600 error messages on the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 KPS–27 operating state indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Typical fault profiles, causes, elimination of faults . . . . . . . . . . . . . . . . . 15

6.1 Fault profiles related to the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.1 System does not boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.2 System does not boot, display stays dark, no acoustic signal (PC loudspeaker) . . . . . . . . 15
6.1.3 Sporadic: system does not boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.4 System does not boot, display stays dark, short acoustic signals (PC loudspeaker) . . . . . 16
6.1.5 System is switched on, acoustic error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1.6 Display stays dark, but system boot normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1.7 System crash when booting, no keyboard entries possible . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1.8 The system repeatedly and automatically resets itself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.9 BIOS error message “CMOS Checksum Error” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.10 BIOS error message “MEMORY TEST FAILED” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.11 Cannot boot from hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.12 Cannot access floppy disk drive (FDD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1.13 CD–ROM drawer does not open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1.14 Data cannot be read from the CD–ROM drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1.15 The mouse does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.16 Windows 95 crashes with exceptional error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.17 Controller freezes on “Stop 0” when running up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.18 GUI does not boot, and is aborted with a General Protection fault . . . . . . . . . . . . . . . . . . . . 19
6.2 Fault profiles related to DSE machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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6.2.1 Program crashes (some with loss of mastering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.2.2 The robot does not move in jog mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.3 The drives cannot be switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 DSE error messages when booting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.1 DSE x not found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.2 Memory test error DSE x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.3 DSE x does not run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.4 DSE axis assignment Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.5 Power module axis Ax not / incorrectly connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3.6 Machine data loader cancelled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3.7 Incorrect machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4 DSE error messages during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4.1 Watchdog interpolation cycle Axis x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4.2 Synchronization error with DSE Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4.3 Regulator limit exceeded Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4.4 Stopped Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4.5 Motor temperature Ax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5 Fault profiles related to the MFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5.1 Controller freezes on “Stop 0” when running up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5.2 EMERGENCY STOP channel x does not work or is always active . . . . . . . . . . . . . . . . . . . . 25
6.5.3 KCP control panel does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5.4 No image on KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5.5 I/Os (inputs/outputs) faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5.6 Operating mode switchover on KCP does not react . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5.7 When controller is booted, the kernel system VxWorks does not run up . . . . . . . . . . . . . . . 26
6.5.8 Network card is not detected by Windows 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.6 Fault profiles related to the KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.6.1 No display on the LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.6.2 Drives cannot be switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.6.3 No entries can be made via KCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.6.4 EMERGENCY STOP cannot be acknowledged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.6.5 Display is too bright and cannot be set in the usual way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.6.6 Space Mouse does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.7 Fault profiles related to the Interbus card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.7.1 Communication via diagnostic interface not possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.7.2 Error message “Interbus I/O driver configuration error” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.7.3 After inserting the IBS card: no display, controller does not boot (Stop 0) . . . . . . . . . . . . . . 29
6.7.4 The controller “hangs” after initialization of the IBS card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.7.5 The hard drive (HDD) is not detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.7.6 No external power supply for slave when controller switched off . . . . . . . . . . . . . . . . . . . . . . 29
7 DSE–RDW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 [1] or [M] RDW display table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3 [3] or [O] RDW adjust offset and symmetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.4 [5] or [Q] RDW adjust hardware configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.5 [6] or [B] RDW adjust phase shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.6 [7] or [S]RDW check communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.6.1 [8] or [T] MFC display register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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7.7 [A] RDW set offset and symmetry to default values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.8 [B] RDW store table to hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.9 [C] Servo bus diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.9.1 Error messages valid for the KPS–600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.9.2 Error messages valid for the KSDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.10 [D] Information about the DSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8 Robot repair card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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1 Fundamentals
1 Fundamentals
1.1 Repairs
G Repairs to the robot system may only be carried out by KUKA customer support
personnel or by customers authorized to do so after participation in a relevant service
seminar.
Observe the documentation “Safety – General” and the directives for

handling electrostatic sensitive devices (ESD)!
G Customer repairs are limited to the exchange of modules, e.g. PC power supply unit,
MFC2, DSE–IBS3, KVGA, field bus card, PC drives, servo drive modules, etc. A
defective motherboard, on the other hand, is counted together with the PC housing as
a single exchange part and is therefore not exchanged separately.
G Repairs to individual modules, e.g. servo drive modules, KCPs and cards, may only be
carried out by specially trained personnel from KUKA Roboter GmbH.
1.2 Procurement of spare parts

The exchanged parts should be sent back to KUKA Roboter GmbH with a detailed
description of the fault in compliance with our quality management (QMB) specifications (see
form in Appendix).
Generally speaking, the customer cannot wait for the part to be repaired. A replacement part,
corresponding to a valid manufacturer’s release, is therefore delivered instead.
In the event of defective modules in the PC chassis, we recommend exchanging the
complete PC chassis for repair at KUKA Roboter GmbH.
A repair by KUKA Roboter GmbH carries the following guarantees:
G repair carried out by specially trained, experienced personnel
G compliance with the ESD directives
G use of the necessary 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.
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2 Procedure for fault analysis and elimination

The following procedure is recommended for isolating the cause of the fault:
2.1 Exact analysis of the fault profile

G When did the fault first arise?
– Was the occurrence of the fault immediately preceded by a change to the system?
– Has the cabinet/robot been transported, converted, relocated or reconfigured?
– Have any changes been made to the hardware or software?
G What error messages are displayed in the message window?
– Make a note of any error message numbers and look up more detailed information in
Section 3 (Error messages / troubleshooting).
G Does the fault profile suggest hardware problems?
– Check all LEDs on the DSE–IBS, servo drive modules, RDC, KPS 600, KPS 27
– Check the connection cables.
G Is a peripheral interface signal missing?
G Is it a sporadic fault?
– Make a note of the exact “pre–event history”
– If possible, try to reproduce the fault.
2.2 Comparison with typical fault profiles

The following sections (Typical fault profiles, causes, elimination of faults) are useful for pin–
pointing the component(s) that may be defective.
2.3 Isolation of faults by exchanging components

Exchange the component(s) you suspect to be faulty, one after the other, replacing them with
new components or ones that you know for certain to be fully functional.
The component test stand offers you the possibility of doing exactly the opposite: here you
replace the functioning components with the supposedly defective ones and check whether
or not they function.
2.4 Set analysis settings to output state

Once the fault has been eliminated, make sure that everything that you have removed or
deactivated is made operational again. Finally, you can carry out a function test on the
exchanged components (see previous chapter).
2.5 Final function tests

Carrying out specifically targeted function tests allows you to check that the controller or
robot is functioning absolutely correctly. Occasionally, new faults may be caused during the
fault elimination process, e.g. cables incorrectly connected, etc.
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3 Servo drive module messages and error displays
3 Servo drive module messages and error displays

In the event of a drives error, messages are displayed in several ways.
3.1 Servo drive module LEDs (KSD1)

Important states and faults are indicated directly on the KSDs by means of the two LEDs
situated on the top right–hand side of the servo drive modules.
rd gn
Fig. 1 Servo drive module LED indicator
Red LED Green LED Meaning (message/fault is present)

Off Off No 24 V voltage
On Off Undefined drive controller state
Flashes quickly Flashing quickly (UIC > Ulimit) Fault is present
Flashes slowly Flashing slowly (UIC < Ulimit) Message is present (except in case of undervoltage
Flashing quickly (UIC > Ulimit) UIC) [default threshold 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
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3.2 KCP messages for drives diagnosis

The following KSD error messages are displayed in the message window of the
KCP.
Display in mes- Meaning/cause of error Troubleshooting/possible fault elimi-

sage window nation
DRIVES ERROR KSD is in a fault state; robot carries out See detailed error message which is also
Ax No.: TRIP Emergency Stop. displayed.
OVERCURRENT I*t overload Axis overloaded; reduce load on axis
Ax (reduce OVR, $ACC_AXIS).
SYNCHRONISA- Max. permissible number of communica- Check Interbus cable between DSE,
TION ERROR tion errors with the servo bus exceeded, KPS and KSDs.
DRIVE MODULE or too many toggle bit errors in succes-
Ax sion, causes short–circuit braking.
HEAT SINK TEM- Overtemperature, heat sink Check cabinet cooling circuit/fans;
PERATURE Ax reduce load on axis (reduce OVR,
$VEL_AXIS or $ACC_AXIS).
Parameter error Ax Checksum error in parameter set 1 Check KSD/restart/exchange
PR1
Parameter error Ax
Cxxxx
MOTOR CABLE Ax Power unit overcurrent (short–circuit or Check motor cable/motor
ground fault), hardware monitoring
Ground fault, software monitoring
FAILURE OF Motor phase failure Check motor cable/motor
MOTOR PHASE Ax
Drives error Ax Checksum error in the control unit device Check KSD/restart/exchange
no.: 105 set
Drives error Ax Microcontroller crash Check KSD/restart/exchange
no.: 71
Drives error Ax Communication error with EEPROM in Check KSD/restart/exchange
no.: 79 the control unit
Drives error Ax Communication error with the EEPROM Check KSD/restart/exchange
no.: 80 in the power unit
Drives error Ax Checksum error in the power unit device Check KSD/restart/exchange
no.: 106 set
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4 KPS–600 messages and error displays
4 KPS–600 messages and error displays

4.1 Supply unit KPS–600/10 and /20 LED indicators
Six LEDs can be seen on the control card on the KPS–600. The two upper LEDs (left red,
right green) indicate internal states of the KPS. The 2 red LEDs in the lower group of four
are reserved for the safety logic and are not yet assigned. The two green LEDs in the lower
group of four indicate the state of the brake control.
1 2
3 4
5 6
KPS–600
Fig. 2 KPS–600 LED indicator
Legend
[1] Indication of internal KPS states (red)
[2] Indication of internal KPS states (green)
[3] Reserved for the safety logic (red)
[4] Indication of the state of the brake control (green)
[5] Reserved for the safety logic (red)
[6] Indication of the state of the brake control (green)
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4.1.1 States of the two top LEDs
Green LED Red LED Priority* Meaning

OFF OFF Processor without power supply
Flashes at 1.5 Hz Intermediate circuit voltage under 60 V
ON Intermediate circuit voltage over 60 V
Flashes at 6.1 Hz 1 Communication error
Flashes at 3.1 Hz 2 Brake error
OFF Continuously lit 3 K1 stuck
Flashes 5 times at 1.5 Hz 4 Fault in the BEA signal
(signal for flow of current through the bal-
last resistor)
Flashes 4 times at 1.5 Hz 5 Ballast error
Flashes 3 times at 1.5 Hz 6 Overvoltage in intermediate circuit
Flashes 2 times at 1.5 Hz 7 Overtemperature in interior / heat sink
Flashes once at 1.5 Hz 8 Fault in the low voltage supply (27 V not
present)
*If more than one fault occurs simultaneously, the fault with the smallest priority number will
be displayed. (1 = highest priority; 8 = lowest priority)
4.1.2 States of the middle and lower green LEDs
State of the middle green LED Meaning

LED off Robot brakes not controlled
LED on Robot brakes controlled
State of the bottom green LED Meaning

LED off External axis brakes not controlled
LED on External axis brakes controlled
4.1.3 States of the middle and lower red LEDs
Name State of the red LED Meaning

V1 LED on General EMERGENCY STOP
activated
V2 LED on Local EMERGENCY STOP
activated
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4 KPS–600 messages and error displays (continued)
4.1.4 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 Restart/exchange KPS
1
Parameter error PMx control Checksum error in the control unit Restart/exchange KPS
device set
Drives error PMx no.: 71 Microcontroller crash Restart/exchange KPS
Ballast switch energized for too Ixt overload of the brake resistor Ballast resistor defective or not
long PMx during charging during charging correctly connected
Ballast switch energized for too Ixt overload of the brake resistor Ballast resistor defective or not
long PMx during operation correctly connected; deceleration
phases in robot program too long;
use energy recovery unit
Heat sink temperature PMx Overtemperature, heat sink Cabinet ventilation is not working
Cabinet temperature too high Overtemperature, interior Cabinet ventilation is not working
PMx
Drives error PMx no.: 79 Communication error with the EE- Restart/exchange KPS
PROM in the control unit
Watchdog power module PMx Max. permissible number of com- Check IBS – drives cable
munication errors with the servo
bus exceeded, causes short–cir-
cuit braking
Overvoltage PMx during charging Overvoltage in intermediate circuit Mains voltage too high
while charging (transformer may be necessary)
Overvoltage PMx Overvoltage in intermediate circuit Mains voltage too high; ballast
during operation switch defective >> exchange
KPS
Undervoltage PMx Low voltage supply undervoltage Check low–voltage supply (rated
voltage 27.1 V)
Battery voltage too low for battery Battery undervoltage, U<22 V Battery not charged
back–up
Check battery PMx Battery undervoltage, U<19 V
Undervoltage PMx during charging Undervoltage in intermediate cir- Mains voltage too low
cuit while charging, 500 V threshold
not reached
Brake error Ax/PMx channel x Brake error, main axes Brakes not connected or short–
circuit on the brake cable
Brake error Ax/PMx channel x Brake error, external axes Brakes not connected or short–
circuit on the brake cable
Intermediate circuit charging circuit Optocoupler for ballast resistor Restart/exchange KPS
defective PMx current detection signals that no
current is flowing
K1 contactor welded PMx Main contactor K1 stuck Exchange KPS
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Operating Handbook
5 KPS–27 operating state indicator

On the KPS–27 are two LEDs, one green and one red, which indicate the operating states
of the low–voltage power supply unit. The meaning of the LEDs is explained in the following
table:
LED indicator State Meaning

Green LED (OK) Lit Normal operation
Red LED (overload) Lit Overload operation
Red LED (overload) Flashes slowly Short–circuit operation
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6 Typical fault profiles, causes, elimination of faults
6 Typical fault profiles, causes, elimination of faults

6.1 Fault profiles related to the PC
6.1.1 System does not boot
Main switch to “ON”, display stays dark, power supply fan and CPU fan do not
work
Possible causes:
– Power supply defective
– Short circuit with a connected device
– Short circuit on the motherboard
Elimination of fault:
– Test power supply with a functional device (disconnect supply to all other devices!).
– Disconnect each device in turn from the power supply unit (drives, plug–in cards),
testing the functionality of the power supply each time.
– If the power supply and all other devices are operational, the fault probably lies in the
motherboard.
The power supply must never be operated with no load, i.e. there must
always be at least one device connected to the power supply!
6.1.2 System does not boot, display stays dark, no acoustic signal (PC loudspeaker)
Possible causes:
– IDE1 data cable is incorrectly connected
– Defective expansion card (e.g. Interbus, Ethernet card)
– Defective motherboard
– Connect data cable correctly: The IDE data cable is connected in such a way that the
red marking on the ribbon cable is aligned not with pin 1 but with pin 40 (only IDE
cable!).
– Disconnect expansion cards (e.g. Interbus, Ethernet card) and test again; replace
expansion cards if necessary.
– Exchange motherboard
6.1.3 Sporadic: system does not boot

Display stays dark, no acoustic signal (PC loudspeaker)
Possible causes:
– Incorrect BIOS version
– Carry out BIOS update
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Operating Handbook
6.1.4 System does not boot, display stays dark, short acoustic signals (PC loudspeaker)
Possible causes:
– Memory modules (RAM modules) are not correctly snapped into place (contact fault)
– Memory modules defective
– Snap memory modules correctly into place
– Exchange memory modules
6.1.5 System is switched on, acoustic error messages

List of acoustic error messages:
Signal Meaning
Continuous tone Supply defective, power supply unit faulty
Short tones (continuous) Motherboard defective, memory modules defective
1 x long, 2 x short (K)VGA fault
6.1.6 Display stays dark, but system boot normally

Possible causes:
– KVGA defective
– KCP2 connecting cable snapped
– 24 V supply voltage for KCP2 not present in MFC2
– Exchange KVGA
– Exchange KCP2 connecting cable (between KVGA and X19)
– Exchange connecting cable (X3) from the ESC–CI board to the MFC (X807)
– Exchange safety logic
6.1.7 System crash when booting, no keyboard entries possible

Possible causes:
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6 Typical fault profiles, causes, elimination of faults (continued)
6.1.8 The system repeatedly and automatically resets itself

Possible causes:
– Memory modules defective or combination of different module types used if resets
occur regularly during memory check
– Defective or incorrectly installed graphics card
– Check if different memory module types have been installed (nine–chip and
three–chip modules, access time) and install identical module types if necessary.
– Exchange defective memory modules
– Check KVGA for correct fit in PCI slot, exchange
6.1.9 BIOS error message “CMOS Checksum Error”

Possible causes:
– Incorrect or missing entries in CMOS setup
– RTC chip with integrated CMOS memory on motherboard defective
– Check entries in CMOS setup and make new settings if necessary
6.1.10 BIOS error message “MEMORY TEST FAILED”

Possible causes:
– Defective memory module(s)
– Exchange memory module(s)
6.1.11 Cannot boot from hard disk

Possible causes:
– Hard disk is not correctly entered in CMOS setup
– Hard disk cables/CD–ROM cables (data cable, power supply) not connected or
incorrectly connected
– Master/Slave configuration of the IDE drives is incorrect
– Hard disk defective
– Data cable defective or power supply interrupted
– IDE interface on motherboard defective
– Check accuracy of hard disk parameter entries in “Standard CMOS Setup”
– Check correct connection of the data cable and the power supply
– Check Master/Slave configuration
– Hard disk, exchange data cable
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Operating Handbook
6.1.12 Cannot access floppy disk drive (FDD)

Possible causes:
– FDD not correctly entered in CMOS setup or FDD controller deactivated
– FDD data cable and power supply not connected correctly
– FDD defective
– FDD interface on motherboard defective
– Check CMOS settings
– Connect data cable and power supply correctly
– Exchange FDD
6.1.13 CD–ROM drawer does not open

Possible causes:
– Power supply cable is damaged, incorrectly connected or not connected
– CD–ROM drive faulty
– Connect power supply cable correctly
– Exchange CD–ROM drive
6.1.14 Data cannot be read from the CD–ROM drive

Data cannot be read from the CD–ROM drive, but the CD–ROM drawer does
open
Possible causes:
– Is the CD–ROM drive detected when booting (for motherboards 5VA2, following entry:
“Pri. Slave Disk : CD–ROM, Mode 3” in the window “System Configuration”)?
– The two ends of the interface cable are not connected or incorrectly connected
– Interface cable is damaged
– CD–ROM inserted incorrectly
– Has the system (with CD–ROM drive) recently been moved from a cold environment
to a warm one (e.g. initial start–up)?
– CD–ROM drive faulty
– Connect interface cable correctly
– Replace interface cable
– Insert CD–ROM correctly (label upwards!)
– It can happen that condensation gathers on the lens. Remedy: Leave the CD–ROM
drive switched on for about an hour before use
– Exchange CD–ROM drive
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6.1.15 The mouse does not work
The mouse must already be connected when the system is booted; i.e. it cannot be
connected later like the keyboard.
Possible causes:
– Incorrect interface entries in CMOS setup
– COM1 and COM2 connections on the motherboard interchanged; connector
incorrectly connected/connected wrong way round
– Cable with 9–pole or 25–pole connector defective
– Check and if necessary correct entries in CMOS setup
– Check connections on the motherboard
– Replace interface cable with connector
6.1.16 Windows 95 crashes with exceptional error

Possible causes:
6.1.17 Controller freezes on “Stop 0” when running up

Possible causes:
– MFC incorrectly connected
– MFC defective
– Additional expansion card (e.g. Interbus) interfering with functioning of MFC
– ISA bus on motherboard faulty
– Check for correct fit of MFC
– Remove expansion card and run controller up again
– Exchange MFC
6.1.18 GUI does not boot, and is aborted with a General Protection fault
Possible causes:
– Defective files in the software installation
– Settings in CMOS setup incorrect
– Check settings in CMOS setup
– Reinstall control software
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Operating Handbook
6.2 Fault profiles related to DSE machine data
6.2.1 Program crashes (some with 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.
6.2.2 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.
(1) Is the entry Office=FALSE present in the file hw_inf.ini in the directory
C:\KRC\Roboter\init?
(2) Does the directory C:\KRC\Roboter\KRC\mada contain the correct machine data?
If no machine data have been copied into the directory, the standard machine data in the
system are used for the Office Version, i.e. the axes are all in axis simulation mode.
G 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.
Further information on the “Robot name” can be found in the Operating Handbook, in the
chapter [Start–up] in the section “Configuring the system”.
G 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.
G If the machine data are incorrect, copy the correct machine data from the CD into the
directory C:\KRC\Roboter\KRC\mada.
Further information on “Modify variable” can be found in the Operating Handbook, in the
chapter [Start–up], in the section “Configuring the system”.
With the GUI (graphical user interface) active, the machine data are overwritten
again during the Power Off backup. =>Either exit the GUI beforehand, by means of
EXIT, or carry out a controlled exit from the boot sequence and change the machine
data.
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6.2.3 The drives cannot be switched on

(1) Is the DSE a series DSE?
G If the DSE is working correctly an LED flashes on the KPS–600 connector.
(2) Is the peripheral connector X11 plugged in?
G If the connector is not connected or is incorrectly wired, the message “EMERGENCY
STOP” or “Driving condition” or “Operator safety” is displayed.
(3) Has the DSE booted?
G If the DSE has booted, the LED on the DSE flashes.
(4) Is the “Emergency Stop”/enabling channel duality correct?
G If the Emergency Stop button or enabling switch is released slowly, the dual–channel
relays can reciprocally interlock. The problem can be solved by pressing and unblocking
the Emergency Stop button again.
(5) Is the controller’s real–time kernel still running?
G The task, which constitutes the interface to the DSE, must cyclically trigger a watchdog
on the MFC in order to be able to switch the drives on. If the kernel system is running,
this enables you to establish, for example, whether or not an override modification has
been successful.
(6) Is there an encoder error present at any axis?
G If there is an encoder error, the controller cancels the RC Ready signal on the MFC and
the drive contactors drop out.
(7) Is there a servo drive module error message?
G If certain servo drive module error messages occur, the power module switches the
drives off automatically. These messages include, for example, “Overcurrent” and
“Overvoltage”.
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Operating Handbook
6.3 DSE error messages when booting
6.3.1 DSE x not found

The MFC checks to see if it can detect a connected DSE. This error message is generated
if the controller needs the DSE for control purposes and the detection function indicates that
no DSE is connected. The loading of the machine data is canceled as the data cannot be
loaded into the DSE; when this error occurs the following follow–up message is generated:
DSE axis assignment Ax, machine data loader canceled, erroneous %1 machine data.
Possible causes:
– No DSE is connected.
– The DSE is incorrectly configured.
– The DSE is defective.
– The MFC is defective.
6.3.2 Memory test error DSE x

If a DSE was detected, a memory test is carried out in the dual–port memory. The error
message is generated if this memory test fails. The loading of the machine data is canceled
as the data cannot be loaded into the DSE; when this error occurs the following follow–up
message is generated: DSE axis assignment Ax, machine data loader canceled, erroneous
%1 machine data.
Possible causes:
– DSE dual–port memory defective.
– Another card is connected to the ISA bus interfering with the bus access to the DSE
memory.
6.3.3 DSE x does not run up

The DSE has no EPROM with the control software; instead, the software is downloaded onto
the DSE every time the system is booted. The error message is generated if the DSE does
run up with this software. The loading of the machine data is canceled as the data cannot
be loaded into the DSE; when this error occurs the following follow–up message is
generated: DSE axis assignment Ax, machine data loader canceled, erroneous %1 machine
data.
Possible causes:
– DSE is incorrectly configured (jumper)
– DSE defective
6.3.4 DSE axis assignment Ax

Either one of the previous errors has occurred and the error is merely a follow–up message
or the axis assignment with $DSECHANNEL is incorrect.
Possible causes:
– $DSECHANNEL incorrect axis assignment
– DSE, MFC defective (follow–up message)
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6.3.5 Power module axis Ax not / incorrectly connected

The current calibration of the axes is compared with the value $CURR_CAL in the machine
datum. The message is generated if the axis connector to the power module is incorrectly
connected.
Further possible causes:
– MFC/DSE or power module function faulty.
– Ribbon cable between DSE and power module incorrectly connected or defective.
– ISA bus on motherboard possibly faulty.
6.3.6 Machine data loader cancelled

or other machine data in the machine data list are incorrect.
6.3.7 Incorrect machine data

or other machine data in the machine data list are incorrect.
More detailed information on correcting the machine data can be found in the section
“6.2 Fault profiles related to DSE machine data”.
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Operating Handbook
6.4 DSE error messages during operation

6.4.1 Watchdog interpolation cycle Axis x
The interpolator feeds the DSE every interpolation cycle (distance per interpolation cycle).
If no feed is written to the DSE interface during a cycle the watchdog responds, i.e. the
interpolation has missed an interpolation cycle.
6.4.2 Synchronization error with DSE Ax

The interpolator feeds the DSE every interpolation cycle (distance per interpolation cycle).
If the DSE has retrieved the last feed from the interface, the watchdog responds.
6.4.3 Regulator limit exceeded Ax

The position controller output has gone into limitation, i.e. the axis does not follow the
command value.
Possible causes:
– The motor is blocked, e.g. because the brake does not release, the robot has had a
collision or the axis has reached a buffer.
– The acceleration is too high, e.g. because incorrect machine data have been loaded,
the wrong weight has been entered in $LOAD or the weight of the tool is too high.
– There is no servo–control of the motor, e.g. because the enable command is missing
(power module defective), the motor cables have been interchanged, the connector
is defective or the motor is not connected.
– The controller amplification is incorrect.
6.4.4 Stopped Ax
The axis has moved outside the standstill window, although the interpolator had not specified
a movement.
Possible causes:
– The brake is defective and the axis sags.
– The weight on the tool is greater than the holding torque of the axis.
– There is no servo–control of the motor, e.g. because the enable command is missing
(power module defective), the motor cables have been interchanged, the connector
is defective or the motor is not connected.
6.4.5 Motor temperature Ax

The permissible motor temperature has been exceeded.
Possible causes:
– The external temperature is too high.
– The encoder cable has become detached.
– There are too few motion pauses in the motion program.
– The axis is sluggish.
– The weight on the flange is too high.
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6.5 Fault profiles related to the MFC
6.5.1 Controller freezes on “Stop 0” when running up

Possible causes:
– MFC cannot be initialized
– MFC incorrectly connected
– Additional expansion card (e.g. Interbus) interfering with functioning of MFC
– ISA bus on motherboard faulty
– Check for correct fit of MFC
– Remove expansion card and run controller up again
– Exchange MFC
6.5.2 EMERGENCY STOP channel x does not work or is always active

Possible causes:
– EMERGENCY STOP circuit on MFC defective
– Servo drive module, DSE–IBS3 or ESC node, etc. defective
– Exchange MFC
– Exchange other components
6.5.3 KCP control panel does not work

Possible causes:
– CAN controller on the MFC faulty, connecting cable defective
– KCP, cable or Harting connector faulty
– Exchange MFC
– Exchange KCP
6.5.4 No image on KCP

Possible causes:
– Power supply to X5 for KCP missing
– KCP, cable or Harting connector faulty
– Exchange MFC
– Exchange KCP
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Operating Handbook
6.5.5 I/Os (inputs/outputs) faulty

Possible causes:
– Ribbon cable to X11 faulty or damaged
– I/Os to X808 faulty
– Replace ribbon cable
– Exchange MFC
6.5.6 Operating mode switchover on KCP does not react

Possible causes:
– Mode detection on MFC defective
– Mode selector switch on KCP, cable or Harting connector faulty
– Exchange MFC
– Exchange KCP
6.5.7 When controller is booted, the kernel system VxWorks does not run up
Possible causes:
– MFC cannot trigger interrupt because incorrectly configured (jumper)
– MFC defective
– Check configuration, make settings if necessary
– Exchange MFC
6.5.8 Network card is not detected by Windows 95

Possible causes:
– MFC–Ethernet settings incorrect
– Ethernet interface on MFC defective
– Check Ethernet configuration using “EZSTART” and make any necessary settings
– Exchange MFC
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6.6 Fault profiles related to the KCP
6.6.1 No display on the LCD

Possible causes:
– Connecting cable defective (open circuit)
– Harting connector insert pushed in
– KVGA defective
– KCP defective
– Exchange KVGA
– Exchange KCP
6.6.2 Drives cannot be switched on

Possible causes:
– Enabling switch stuck (old release?)
– Harting connector insert pushed in, open circuit
– KCP defective
– Enabling circuit only single–channel
– Exchange KCP
– Exchange MFC
6.6.3 No entries can be made via KCP

Possible causes:
– MFC defective (CAN bus)
– KCP defective
– Exchange MFC
– Exchange KCP
6.6.4 EMERGENCY STOP cannot be acknowledged

Possible causes:
– EMERGENCY STOP button defective
– Exchange KCP
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Operating Handbook
6.6.5 Display is too bright and cannot be set in the usual way
Possible causes:
– KCP (EEPROM) is incorrectly programmed
– Display defective
– Load the tool “CONDRV” in order to correct the contrast setting (see Technical Memo
“KCP contrast problem”)
– Exchange KCP
6.6.6 Space Mouse does not work

Possible causes:
– MFC defective (CAN bus)
– Space Mouse defective
– Exchange KCP
– Exchange MFC
6.7 Fault profiles related to the Interbus card
6.7.1 Communication via diagnostic interface not possible

Possible causes:
– Data cable, periphery faulty
– Diagnostic interface on IBS card defective
– Work on data cable, periphery
– Replace the IBS card.
6.7.2 Error message “Interbus I/O driver configuration error”

Possible causes:
– IBS card incorrectly configured
– IBS card cannot be initialized
– Check configuration
– Replace the IBS card.
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6.7.3 After inserting the IBS card: no display, controller does not boot (Stop 0)
Possible causes:
– The IBS card is defective.
– 16 bit access to IBS does not work
– IBS card interferes with MFC function
– Exchange IBS card
6.7.4 The controller “hangs” after initialization of the IBS card

Possible causes:
6.7.5 The hard drive (HDD) is not detected

Possible causes:
– Address conflict with IDE controller
6.7.6 No external power supply for slave when controller switched off
Possible causes:
– IBS filter defective or not correctly connected
– External power supply input on IBS card defective
– Exchange IBS filter (if fiber–optic cable)
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Operating Handbook
7 DSE–RDW
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.
“DSE” is the abbreviation for “Digital Servo Electronics”, a module fitted on the MFC card in
the control cabinet. “RDW” is the German acronym for “Resolver–Digital Converter (RDC)”.
This unit is located at the robot base.
Selecting the menu item “Setup – Service – DSE – RDW”
opens this window for language selection:
Briefly press the “N” key on the keyboard to display the following menus in English.
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7 DSE–RDW (continued)
7.1 Main menu
The value of the DSE interrupt counter is displayed in the bottom line. Incrementation of this
hexadecimal counter indicates that the DSE control program is running. If the counter stops,
the DSE control program is not running correctly.
If you wish to select a submenu, press the preceding figure or letter on the keyboard of your
KCP. You can quit the program or selected submenu immediately at any time by pressing
the “ESC” key.
The version number of the DSE–RDW diagnostic tool is displayed at the top right–hand side
of the display.
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.
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Operating Handbook
7.2 [1] or [M] RDW display table
If you have selected this option in the main menu, the contents of the screen illustrated above
appear on your display. Measurement and configuration data of the RDW are displayed here.
It is possible to page through the table using the keys “PGUP” and “PGDN”. These functions
are available in the numeric keypad. However, this must first be switched to control functions.
To do this, press the “NUM” key at the top left of the keypad. So doing, observe the left–hand
side of the status line in the display. The word “NUM” must be displayed faded out.
Press the space bar at the bottom right of the keyboard to refresh the display. You can quit
the submenu immediately at any time by pressing the “ESC” key.
In line 88 (index) are data concerning the hardware configuration of the RDW. The frequency
set must agree exactly with the processor and processor quartz frequencies, otherwise
encoder errors will occur in every axis. If the frequency has not been set correctly, it can be
altered using menu item “5”.
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7.3 [3] or [O] RDW adjust offset and symmetry
Set the RDW offset and symmetry values to the default values.
Then select this menu item and move ALL robot axes in jog mode, first in the
positive direction and then in the negative direction.
This function is used to adjust the sine, cosine, offset and symmetry of the RDW. Existing
A/D converter offsets and resolver asymmetries are eliminated in this way. The adjustment
is carried out automatically based on the maximum sine and cosine values measured.
In order to be able to determine the maximum sine and cosine values correctly, every axis
must have been moved through several revolutions of the motor.
After adjustment, the determined values are displayed for control purposes:
When the offset and symmetry values are checked, it is only necessary to detect extreme
irregularities, e.g. if the axis did not move or a module is defective. Only axes connected to
the RDW are relevant.
The values can lie between –1500 ... 1600 for the offset and between 18000 ... 22000 for
the symmetry and depend heavily on the built–in A/D converter or multiplexer.
If the values lie outside these ranges, press the “N” key on the keyboard. In this way the RDW
is reset to its default values.
If you press any other key, the values are accepted by the RDW and saved in the EEPROM.
7.4 [5] or [Q] RDW adjust hardware configuration
Do not select this menu item; this function is reserved for our service
department.
7.5 [6] or [B] RDW adjust phase shift
Do not select this menu item; this function is reserved for our service
department.
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Operating Handbook
7.6 [7] or [S]RDW check communication

The RDW sends 12 data words to the DSE in a 125 µs cycle. This function can be used to
check the communication between the DSE and the RDW. In this function, all values are
displayed in hexadecimal.
Command
The last command the DSE has sent to the RDW. The hexadecimal value of this data
word is always between 4000 ... 4007. The refresh rate of the KCP’s LCD display is not
high enough, however, for you to be able to see all the values consecutively.
Axis nn
This data word displays the resolver positions of the individual axes. It is normal for the
values to vary. If an axis displays the value zero, there is an encoder error.
Value
The motor temperature of axes 1 to 8 requested by the DSE by means of the command.
Error
The encoder error bits and EMT signals are encoded in this data word.
Byte 15
Byte 14
Byte 13
Byte 12
Byte 10
Byte 11
Byte 9
Byte 8
Byte 7
Byte 6
Byte 5
Byte 4
Byte 3
Byte 2
Byte 1
Byte 0
EMT Encoder error bits for the robot axes

insignificant for diagnosis
signals A8 A7 A6 A5 A4 A3 A2 A1
ChkSum
Check sum for all transferred data.
Communication error state
If more than three data transfers have failed consecutively, this is displayed here. The
state then takes the value 0001.
Press the Enter key to reset the state.
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Communication error counter

All transfers containing errors are counted here.
The display is frozen by pressing the space bar at the bottom right of the keyboard and
refreshed by pressing it again. Pressing the “TAB” key switches back to the cyclical display.
This function is available in the numeric keypad. However, this must first be switched to
control functions. To do this, press the “NUM” key at the top left of the keypad. While doing
this, observe the left–hand side of the status line in the display. The word “NUM” must be
displayed faded out.
You can quit the program or selected submenu immediately at any time by pressing the
“ESC” key.
7.6.1 [8] or [T] MFC display register
Inputs 1–8, inputs 9–16

These registers show the states of MFC inputs 1 ... 8 and 9 ... 16.
The levels are displayed inverted.
Safety logic
LOW level signifies
Offset Abbr. Function, meaning
...
Bit 0 NotAus1 Image of Emergency Stop circuit 1 Circuit open
Bit 1 NotAus2 Image of Emergency Stop circuit 2 Circuit open
Bit 2 NotAusD EMERGENCY STOP delay Delay active
Bit 3 Zust1 Image of enabling switch circuit 1 Circuit closed
Bit 4 Zust2 Image of enabling switch circuit 2 Circuit closed
Bit 5 Test Image of operating mode group “TEST” Group selected
Bit 6 Auto Image of operating mode group “AUTO” Group selected
Bit 7 0 – –
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Operating Handbook
Status register
LOW level signi-
Offset Abbr. Function, meaning
fies ...
Bit 0 DSEVor1 Image of first DSE Circuit open
Bit 1 DSEVor2 Image of second DSE Circuit open
Bit 2 Err01 Monitoring of outputs 1 ... 8 Short–circuit
Bit 3 Err02 Monitoring of outputs 9 ... 16 Short–circuit
Bit 4 OTEMP Image of control computer temperature Overheated
Bit 5 1 – –
Bit 6 SADR MFC base address h280 [HI h260]
Bit 7 WDT MFC watchdog Tripped
The display is frozen by pressing the space bar at the bottom right of the keyboard and
refreshed by pressing it again. Pressing the “TAB” key switches back to the cyclical display.
This function is available in the numeric keypad. However, this must first be switched to
control functions. To do this, press the “NUM” key at the top left of the keypad. While doing
this, observe the left–hand side of the status line in the display. The word “NUM” must be
displayed faded out.
You can quit the program or selected submenu immediately at any time by pressing the
“ESC” key.
7.7 [A] RDW set offset and symmetry to default values
This menu item can be used to reset the offset and symmetry values to the default values.
This should always be done before an RDW adjustment is carried out.
RDW adjustment
G Set RDW to default values
G Jog all axes, guide value: min. 10 degrees per axis
G Carry out offset and symmetry adjustment
7.8 [B] RDW store table to hard disk
Selecting this option saves the contents of the RDW table to the hard disk.
7.9 [C] Servo bus diagnosis
Servo bus diagnosis is used to read error and status data between from the KPS and the
KSDs.
36 of 43
Using the [U] or [D] key (or the arrow keys), position the arrow, on the left–hand side of the
window, next to the number of the device you wish to display. Confirm the selection by
pressing the [S] key.
Example selection Module Nr. 1 (KPS–2)
The current status is displayed. In order to read the contents of the buffer (the last three
errors), enter the required memory location: for the current error, enter [1] or [2] and 161; for
the last error, enter 162; for the second to last error, 163, and for the third to last, 164. The
error codes generated correspond to the IBS trip numbers, the meaning of which can be seen
in the following table.
Example selection [E] IBS device info
7.9.1 Error messages valid for the KPS–600

IBS trip number Lecom fault Message text Meaning
number
0 0 “ok” Device state OK
1 72 “Pr1 trip” Checksum error in parameter set 1
3 105 “HO5 trip” Checksum error in the control unit device set
5 71 “CCr trip” Microcontroller crash
6 11 “OC1 trip” Ixt overload of the brake resistor while charging
8 15 “OC5 trip” Ixt overload of the brake resistor during operation
10 50 “OH trip” Overtemperature, heat sink
37 of 43
Operating Handbook
39 52 “OH2 trip” Overtemperature, interior
24 79 “Pr5 trip” Communication error with the EEPROM in the

control unit
28 65 “CE4 trip” Max. permissible number of communication errors

with the servo bus exceeded, causes short–circuit
braking
35 131 “OV1 trip” Overvoltage in intermediate circuit while charging
36 132 “OV2 trip” Overvoltage in intermediate circuit during opera-

tion
19 32 “LP1 trip” Mains phase failure
31 121 “LV1 trip” Low voltage supply undervoltage
32 122 “LV2 trip” Battery undervoltage, U<22 V
33 123 “LV3 trip” Battery undervoltage, U<19 V
34 124 “LV4 trip” Undervoltage in intermediate circuit while char-

ging, 500 V threshold not reached
41 141 “BR1 trip” Brake error, main axes
30 142 “BR2 trip” Brake error, external axes
37 112 “BEA trip” Optocoupler for ballast resistor current detection

signals that no current is flowing
40 111 “K1 trip” Main contactor K1 stuck
7.9.2 Error messages valid for the KSDs
(valid from Firmware V0.3 onwards)
IBS trip number Lecom fault Message text Meaning

number
0 0 “ok” Device state OK
1 72 “Pr1 trip” Checksum error in parameter set 1
3 105 “HO5 trip” Checksum error in the control unit device set
5 71 “CCr trip” Microcontroller crash
6 11 “OC1 trip” Power unit overcurrent (short–circuit or ground

fault), hardware monitoring
7 12 “OC2 trip” Short–circuit, software monitoring
8 15 “OC5 trip” I*t overload
10 50 “OH trip” Overtemperature, heat sink
11 91 “EEr trip” External error, short–circuit braking requested by

the controller
19 32 “LP1 trip” Motor phase failure
24 79 “Pr5 trip” Communication error with the EEPROM in the

control unit
28 65 “CE4 trip” Max. permissible number of communication errors

with the servo bus exceeded, or too many toggle
bit errors in succession, causes short–circuit bra-
king.
43 80 “PR6 trip” Communication error with the EEPROM in the

power unit
44 106 HO6 trip Checksum error in the power unit device set
38 of 43
7.10 [D] Information about the DSE
39 of 43
Operating Handbook
8 Robot repair card

This form enables us to gather specific, concentrated information about parts or modules that
have failed. In this way we can quickly increase the quality of our robot systems still further.
A B C
D E F G H
I Y K L
M N O P
Q
Fig. 3 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
You can give a more detailed description of the location of the robot system in this box.
Example: Shop 4, UB I, IR 16 B
Box C
The order number is assigned by us to the robot system when the order is processed.
You can either obtain this number from your purchasing team or leave this box empty.
We will then enter the order number later.
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:
40 of 43
8 Robot repair card (continued)
Serial number
Fig. 4 Rating plate on robot base
Box E
The serial number of the robot system can be found here:
Fig. 5 Rating plate
Box F
The serial number of the control cabinet can be found here:
KR C2
0122
00106204
2000
392.750–36...
3x400V
50/60Hz
6A
16A
185kg
12345
Fig. 6 Rating plate on control cabinet
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Operating Handbook
Box G
The serial number of the 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.
KR C2
Fig. 7 Rating plate inside control cabinet
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.
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 (for statistical purposes) 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”.
42 of 43
8 Robot repair card (continued)
Box N
Please enter, in this box, the date on which the fault occurred.
Box O
Please enter, in this box, how many hours the robot system had been used before the
fault occurred.
The number of operating hours can be obtained by dividing the content 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. 8 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”.
Box P
In this box, please 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.
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,
please 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
43 of 43
Index
A M
Analysis of the fault profile, 8 Machine data, 20
MFC, 25
MFC register, 35
C
Causes, 15 P
Procurement of spare parts, 7
D
R
DSE, 20, 30
RDW (RDC), 30
DSE booting, 22
RDW adjust hardware configuration, 33
DSE during operation, 24
RDW adjust offset and symmetry, 33
RDW adjust phase shift, 33
E RDW check communication, 34
RDW display table, 32
Elimination of faults, 15
RDW set offset and symmetry to default values,
Encoder errors, 32 36
Exchanging components, 8 RDW store table to harddisk, 36
Repair card, 40
F
S
Function tests, 8
Servo module LEDs, 9
Supply unit KPS–600 LED indicators, 11
I
Interbus card, 28 T
Isolation of faults, 8 Typical fault profiles, 15
Index – i

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CONTROL CABINET

Issued: 20 Mar 2004 Version: 00

2 Procedure for fault analysis and elimination . . . . . . . . . . . . . . . . . . . . . . . 8

3 Servo drive module messages and error displays . . . . . . . . . . . . . . . . . . 9

4 KPS–600 messages and error displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5 KPS–27 operating state indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Typical fault profiles, causes, elimination of faults . . . . . . . . . . . . . . . . . 15

6.2.1 Program crashes (some with loss of mastering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

8 Robot repair card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Observe the documentation “Safety – General” and the directives for

1.2 Procurement of spare parts

2 Procedure for fault analysis and elimination

2.1 Exact analysis of the fault profile

2.2 Comparison with typical fault profiles

2.3 Isolation of faults by exchanging components

2.4 Set analysis settings to output state

2.5 Final function tests

3 Servo drive module messages and error displays

3.1 Servo drive module LEDs (KSD1)

Fig. 1 Servo drive module LED indicator

Red LED Green LED Meaning (message/fault is present)

Red LED Green LED Meaning (no message/fault)

UIC: intermediate circuit voltage

3.2 KCP messages for drives diagnosis

Display in mes- Meaning/cause of error Troubleshooting/possible fault elimi-

4 KPS–600 messages and error displays

Fig. 2 KPS–600 LED indicator

4.1.1 States of the two top LEDs

Green LED Red LED Priority* Meaning

4.1.2 States of the middle and lower green LEDs

State of the middle green LED Meaning

State of the bottom green LED Meaning

4.1.3 States of the middle and lower red LEDs

Name State of the red LED Meaning

4.1.4 KPS–600 error messages on the KCP

Display in message window Meaning/cause of error Troubleshooting/possible

5 KPS–27 operating state indicator

LED indicator State Meaning

6 Typical fault profiles, causes, elimination of faults

6.1.3 Sporadic: system does not boot

6.1.5 System is switched on, acoustic error messages

6.1.6 Display stays dark, but system boot normally

6.1.7 System crash when booting, no keyboard entries possible

6.1.8 The system repeatedly and automatically resets itself

6.1.9 BIOS error message “CMOS Checksum Error”

6.1.10 BIOS error message “MEMORY TEST FAILED”

6.1.11 Cannot boot from hard disk

6.1.12 Cannot access floppy disk drive (FDD)

6.1.13 CD–ROM drawer does not open

6.1.14 Data cannot be read from the CD–ROM drive

6.1.15 The mouse does not work

6.1.16 Windows 95 crashes with exceptional error

6.1.17 Controller freezes on “Stop 0” when running up

6.2 Fault profiles related to DSE machine data

6.2.1 Program crashes (some with loss of mastering)

6.2.2 The robot does not move in jog mode

6.2.3 The drives cannot be switched on

6.3 DSE error messages when booting

6.3.1 DSE x not found

6.3.2 Memory test error DSE x

6.3.3 DSE x does not run up

6.3.4 DSE axis assignment Ax

6.3.5 Power module axis Ax not / incorrectly connected