Kuka KR C2 User manual

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CONTROL CABINET
KR C2 -- USA edition2005
User Manual
Fault Analysis / Diagnosis
Issued: 20 Dec 2004 Version: 00

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eCopyright 2004
KUKA Roboter GmbH
Zugspitzstrasse 140
D--86165 Augsburg
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

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Contents
1 Repair and procurement of spare parts 7............................
1.1 Customer repair 7...............................................................
1.2 Repair by KUKA service personnel 7...............................................
1.3 Procurement of spare parts 7.....................................................
2 Fault analysis and elimination 8....................................
2.1 Fault analysis 8.................................................................
2.2 Isolation of faults using checklists 8................................................
2.3 Isolation of faults by exchanging components 8......................................
3 Typical fault profiles 9.............................................
3.1 Fault profiles related to the PC 9...................................................
3.1.1 Power supply 9..................................................................
3.1.2 Basic configuration 9.............................................................
3.1.3 Drives 9........................................................................
3.1.4 PC--related peripherals 9.........................................................
3.1.5 Fault profile checklist 10...........................................................
3.2 Fault profiles related to DSE and machine data 15....................................
3.2.1 Program crashes (with possible loss of mastering) 15..................................
3.2.2 The robot does not move in jog mode 15.............................................
3.2.3 The drives cannot be switched on 16................................................
3.3 DSE error messages when booting the system 17.....................................
3.3.1 DSE x not found 17...............................................................
3.3.2 Memory test error DSE x 17........................................................
3.3.3 DSE x does not run up 17..........................................................
3.3.4 DSE axis assignment Ax 18........................................................
3.3.5 Power module axis Ax not / incorrectly connected 18..................................
3.3.6 Machine data loader canceled 18...................................................
3.3.7 Incorrect machine data 18.........................................................
3.4 DSE error messages during operation 19............................................
3.4.1 Watchdog interpolation cycle Ax 19.................................................
3.4.2 Synchronization error with DSE Ax 19...............................................
3.4.3 Regulator limit exceeded Ax 19.....................................................
3.4.4 Stopped Ax 19...................................................................
3.4.5 Motor temperature Ax 19..........................................................
3.5 Fault profiles related to the MFC 20.................................................
3.5.1 Controller hangs when loading software components 20...............................
3.5.2 KCP control panel does not work 20.................................................
3.5.3 No image on KCP 20..............................................................
3.5.4 Operating mode switchover on KCP does not react 21.................................
3.5.5 When PC is booted, the operating system VxWorks does not run up 21..................
3.6 Fault profiles related to the KCP 22.................................................
3.6.1 No display on the LCD 22..........................................................
3.6.2 Drives cannot be switched on 22....................................................

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3.6.3 No entries can be made via KCP 22.................................................
3.6.4 EMERGENCY STOP cannot be acknowledged 23....................................
3.6.5 Space Mouse does not work 23....................................................
3.7 Fault profiles related to a field bus card 24...........................................
3.7.1 Communication via diagnostic interface not possible 24................................
3.7.2 Error message “xxxxx I/O driver configuration error” 24................................
3.7.3 After inserting the field bus card: no display, controller does not boot (Stop 0) 24..........
3.7.4 The controller “hangs” after initialization of the field bus card 24.........................
3.7.5 No external power supply for slave when controller switched off 24......................
4 Servo drive module messages and error displays 25..................
4.1 Servo drive module LEDs (KSD1) 25................................................
4.2 KCP messages for drives diagnosis 26..............................................
5 KPS--600 messages and error displays 27............................
5.1 KPS--600/10 and /20 LED indicators 27..............................................
5.1.1 Meaning of LEDs 1 and 2 28.......................................................
5.1.2 Meaning of LEDs 3 and 4 28.......................................................
5.1.3 Meaning of LEDs 5 and 6 28.......................................................
5.1.4 KPS--600 error messages on the KCP 29............................................
6 KPS--27 operating state indicators 31................................
7 DSE--IBS operating state indicators 32...............................
8 RDC2 operating state indicators 33..................................
9 ESC diagnostic tool 34..............................................
9.1 Softkey bar 35...................................................................
9.2 ESC diagnosis error messages 37..................................................
10 DSE--RDW diagnostic tool 39........................................
10.1 Main menu of the DSE--RDW diagnostic tool 39......................................
10.1.1 Language selection 40............................................................
10.1.2 System info 41...................................................................
10.1.3 MFC2 register display 42..........................................................
10.1.4 DSE IBS information 43...........................................................
10.1.5 Display RDC table 44.............................................................
10.1.6 RDC offset and symmetry adjustment 45............................................
10.1.7 Check RDC--DSE communication 46................................................
10.1.8 Drive bus diagnostics 47...........................................................
10.1.9 Drive bus error list 48.............................................................
10.1.10 Drive bus diagnostics -- KPS--2 49..................................................
10.1.11 Drive bus KSD 1--16 50............................................................
10.1.12 Error messages valid for the KPS--600 51............................................
10.1.13 Error messages valid for the KSDs 52...............................................
11 Oscilloscope 53....................................................
11.1 Display 53.......................................................................
11.1.1 File selection 54..................................................................

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11.1.2 Oscilloscope screen 54............................................................
11.1.3 The information window 55.........................................................
11.1.4 The softkey bar 56................................................................
11.1.5 The color softkeys 56.............................................................
11.1.6 The scaling function 57............................................................
11.1.7 The zoom function 58.............................................................
11.1.8 The Save function 58..............................................................
11.1.9 The r.m.s. value function 58........................................................
11.1.10 Print 60.........................................................................
11.1.11 The cursor functions 60............................................................
11.1.12 The filter function 63..............................................................
11.1.13 Superposing traces 64............................................................
11.1.14 Changing color assignments 66.....................................................
11.1.15 Switching curves on and off 67.....................................................
11.2 Configure 68.....................................................................
11.2.1 General 70.......................................................................
11.2.2 Trigger condition 71...............................................................
11.2.3 Trace status 73...................................................................
11.2.4 Trace data 73....................................................................
11.2.5 Examples of a trace 77............................................................
12 Robot repair card 81................................................

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1 Repair and procurement of spare parts
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1 Repair and procurement of spare parts
Repairs to the KR C may only be carried out by KUKA customer support personnel or by
customers authorized to do so after participation in a relevant KUKA Robot Group service
seminar.
1.1 Customer repair
As far as customer repairs to the KR C are concerned, only the exchange of modules is
envisaged. A defective motherboard is exchanged together with the PC rack.
1.2 Repair by KUKA service personnel
Repairs within modules may only be carried out by specially trained KUKA Robot Group
personnel.
A repair by KUKA Robot Group service personnel carries the following guarantees:
Gcarried out by specially trained, experienced personnel
Gcompliance with the ESD directives
Guse of the required special tools
Goptimal conditions for locating faults and searching for the exact causes
Gtechnical revisions carried out
Goverall test of the PC on completion of repair.
1.3 Procurement of spare parts
The article numbers for spare parts are listed in the electronic spare parts catalog (KUKA
Parts) on a CD--ROM that accompanies every control cabinet.
The KUKA Robot Group supplies the following types of spare parts for KR C repairs:
GNew parts
Once the new part has been installed, the part that has been removed can be disposed
of.
GExchange parts
Once the exchange part has been installed, the part that has been removed is returned
to the KUKA Robot Group.
A “Robot Repair Card” is supplied with the exchange parts.
The Repair Card must be completed (see Chapter 12) and returned to the KUKA Robot
Group.

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2 Fault analysis and elimination
The following procedure is recommended for isolating the cause of the fault and enabling
effective repair of the KRC:
2.1 Fault analysis
Is the fault reproducible?
-- Permanent fault
-- Sporadic fault
Did the fault occur after installation or conversion?
-- Transportation damage
-- Commissioning faults
Did the fault occur during operation?
-- Operator influence, incorrect operation
-- Program modifications
-- Software configuration modifications
Was the fault caused by external factors?
-- Electrical factors such as undervoltage/overvoltage, static electricity, interference fields
-- Mechanical factors such as impact, vibration
-- Environmental factors such as heat, cold, humidity
What is the fault profile?
-- Observe the status of operator control and display elements on the KR C
(switch positions, lamps, LEDs)
-- Interpret error messages in the message window of the KCP
(for more detailed information see Section 3.2 and the following sections)
-- Collate the statuses and error messages of higher--level controllers
(process control systems, automation components)
-- Read logbook entries
2.2 Isolation of faults using checklists
The cause of the fault can be isolated by comparing the fault profile with a list of typical fault
profiles (see Section 3.1.5).
2.3 Isolation of faults by exchanging components
In the case of a potentially defective overall system, functioning modules are introduced
into the system one after the other and changes in the behavior of the system are observed.
In the case of a potentially defective component, this is introduced into a functioning
system and changes in the behavior of the system are observed.

3 Typical fault profiles
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3 Typical fault profiles
3.1 Fault profiles related to the PC
3.1.1 Power supply
The motherboard and drives are supplied with power by an integrated switched--mode power
supply.
Typical power supply fault profiles are:
-- Supply voltage that is characterized by dropouts or spikes
-- Output voltage overload
-- Output voltage failure
-- Internal overheating due to fan failure
-- Defects in power switch and ATX power--on logic
3.1.2 Basic configuration
The processor, main memory, CMOS memory and other hardware are integrated onto the
motherboard.
Typical faults in the motherboard basic configuration are:
-- Memory faults in the CMOS--RAM due to undervoltage in the lithium battery
-- Incorrect BIOS entries
-- Memory faults in the main memory (RAM modules)
-- Overheating due to failure of CPU fan
3.1.3 Drives
The hard drive, floppy disk drive and CD--ROM drive are integrated into the PC chassis.
Typical faults in the drives are:
-- Hard drive defect caused by impact or vibration
-- Data error caused by dust in the floppy disk drive and CD--ROM drive
-- Cabling fault in the IDE bus and floppy disk bus
3.1.4 PC--related peripherals
PC--related peripherals include input and output devices and additional plug--in cards.
Typical faults in the PC--related peripherals are:
-- Keyboard does not respond
-- Monitor display faults
-- Fault in the interplay between the VGA chip and the KVGA card
-- Bus errors and communication errors due to incorrectly configured plug--in cards
(MFC, Ethernet, field bus cards)

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3.1.5 Fault profile checklist
Main switch on PC to “ON”, system fails to boot, display stays dark, power supply
fan and CPU fan do not work
Possible causes:
-- Power supply defective
-- Short circuit on the motherboard
-- Short circuit on a connected device
Elimination of fault:
-- Disconnect all devices from the power supply unit. Switch on PC and measure output
voltages at the power supply unit. If an output voltage is too low, exchange the power
supply unit.
-- Connect the power supply to the motherboard with the power supply unit switched off.
Switch on PC and measure supply voltages at the power supply unit. If an output
voltage is too low, exchange the PC rack (motherboard fault).
-- Reconnect each device in turn to the power supply unit (drives, plug--in cards) with the
power unit switched off. Switch on PC and measure output voltages at the power
supply unit. If an output voltage is too low, exchange the device in question.
System does not boot, display stays dark
Possible causes:
-- Ribbon cable not correctly connected (male connector without coding)
-- Defective expansion card (Interbus, MFC, KVGA)
-- Memory modules (RAM modules) not correctly snapped into place (contact fault)
-- Memory modules defective
-- Defective motherboard
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

3 Typical fault profiles (continued)
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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

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BIOS error message “CMOS Checksum Error”
Possible causes:
-- Undervoltage in lithium battery on the motherboard
-- Incorrect or missing entries in CMOS setup
-- CMOS memory on motherboard defective
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)

3 Typical fault profiles (continued)
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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!)

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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 Typical fault profiles (continued)
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3.2 Fault profiles related to DSE and machine data
3.2.1 Program crashes (with possible loss of mastering)
Faulty cable shields can seriously reduce the controller’s immunity against interference. In
the event of error messages affecting DSE--IBS, yet for which no other cause is apparent,
the connecting cable between the resolver interface and the control cabinet should be
checked.
3.2.2 The robot does not move in jog mode
The robot does not move in jog mode; the brakes and servo enable remain closed. The axis--
specific actual values do change, however.
The following points must be checked:
-- Is the variable value Office=FALSE entered in the file hw_inf.ini?
(Path: C:\KRC\Roboter\init\hw_inf.ini)
-- Are the correct servo files loaded?
-- Are the correct machine data configured?
If no machine data have been copied into the directory, the standard machine data in the
system for the Office version are used, i.e. the axes are all in axis simulation mode.
To check the machine data, carry out the following steps:
-- By pressing the menu key “Configure” and selecting the menu item “Settings” →
“Robot name”, you can see which machine data are present and whether or not they
are valid.
-- By pressing the menu key “Monitor” and selecting the menu item “Modify variable”,
you can check whether or not the correct machine data have been loaded into the
system. $TRAFONAME[ ] (transformation name) must contain the name of the robot
and $AX_SIM_ON (axis simulation) must be zero. If $TRAFONAME[ ] is “OFFICE
ROBOT KR125”, then the machine data are completely missing in the Mada directory.
-- If the machine data are incorrect, copy the correct machine data from the CD into the
directory C:\KRC\Roboter\KRC\mada.
With KUKA HMI active, the machine data are overwritten again during the Power Off backup.
-- Exit the HMI beforehand, by means of EXIT, or
-- Carry out a controlled exit from the boot sequence and change the machine data

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3.2.3 The drives cannot be switched on
-- Is the peripheral connector X11 plugged in?
If the connector is not connected or is incorrectly wired, the message “EMERGENCY
STOP” or “Motion enable” or “Operator safety” is displayed.
-- Has the DSE booted?
If the DSE has booted, the LED on the DSE flashes.
-- Check the E--Stop circuits using the ESC diagnostic tool.
-- Is the VxWorks real--time operating system still running?
-- Is there an encoder error present at any axis?
If there is an encoder error, the controller cancels the RC Ready signal on the MFC
and the brakes are applied.
-- Is there a KSD (KUKA Servo Drive) error message present? Certain errors
(e.g. overcurrent, overvoltage) cause the servo drive module to deactivate the drives
automatically.

3 Typical fault profiles (continued)
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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

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3.3.4 DSE axis assignment Ax
Either the error is merely a follow--up message or the axis assignment with $DSECHANNEL
is incorrect.
Possible causes:
-- DSE, MFC defective (follow--up message)
-- $DSECHANNEL incorrect axis assignment
3.3.5 Power module axis Ax not / incorrectly connected
The current calibration of the axes is compared with the value $CURR_CAL in the machine
data list. The message is generated if the axis connector to the power module is incorrectly
connected.
Further possible causes:
-- MFC/DSE, KPS or KSD function faulty
-- Ribbon cable between DSE and power module incorrectly connected or defective
-- 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 Typical fault profiles (continued)
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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:
GThe 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
GThe 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
GThere 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
GThe 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:
GThe brake is defective and the axis sags.
GThe weight on the tool is greater than the holding torque of the axis.
GThere is no servo--control of the motor because
-- the enable signal is missing (KSD defective)
-- the motor cables have been interchanged or are defective
-- the motor is not connected
3.4.5 Motor temperature Ax
The permissible motor temperature has been exceeded. Possible causes:
-- External temperature is too high
-- Encoder cable is interrupted
-- The motion pauses in the motion program are too short
-- The axis is sluggish
-- The weight on the flange is too high

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3.5 Fault profiles related to the MFC
3.5.1 Controller hangs when loading software components
Possible causes:
-- MFC cannot be initialized
-- MFC incorrectly connected
-- Additional expansion card (e.g. Interbus) interfering with functioning of MFC
-- 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
-- Defective motherboard
Elimination of fault:
-- Restore power supply
-- Exchange KCP
-- Exchange KVGA card
-- Exchange MFC