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KUKA Robot | 100 Common Problems and Solutions

Common problems and solutions of KUKA robots:

1. Why does the robot have the problem of zero point loss?

Whether the zero point of the robot is lost mainly depends on a piece of data carrier (EDS) in the system, which not only affects whether the zero point of the robot is lost during the normal operation of the robot, but also after the robot is shut down. Therefore, during the normal operation of the robot or after the power failure, zero point loss may occur.

2. AMR Touch Screen Abnormality:

Abnormal phenomenon of touch screen, possible causes:

(1) The screen is only on the boot interface/displays the word 'KUKA', and the firmware program is not flashed

(2) Hardware abnormality/damage (touch screen failure, blurred screen)

Solution:

(1) Flash into the touchscreen firmware program

(2) Replace the touchscreen and put it away 

The AMR touch screen is malfunctioning

3. KSS01105

KSS01105 Positioning monitoring (axis number)

Cause:

(1) The wrong mechanical parameters were set. 

(2) The reduction ratio is set incorrectly 

(3) If it is the corresponding A2 shaft, check the balance cylinder for damage or leakage 

(4) Motor reasons 

(5) Cable connection between motor and encoder 

Solution:

(1) Adjust $IN_POS_MA[ ] or $TIME_POS[ ]

(2) Adjust the reduction ratio 

(3) Replace the balance cylinder 

(4) Preventive motor replacement 

(5) Connect the cables correctly 

4. What are the steps required to put a KUKA robot into operation (start-up)?

(1) Pre-boot inspection: 

a. Make sure the ambient temperature is within 5°C-55°C.

b. The body-control cabinet cables and connectors are normal without external injury, and after being connected according to the wire standard, the buckle is firm and there is no shaking.

c. After the power supply cable is energized, open the control cabinet door, close the Q3 switch to open Q1, and measure whether the line voltage of the 3 phases at Q3 is within the range and whether there is any phase loss. Disconnect Q1 and turn on Q3.

(2) Operation of the initial boot: Please refer to the quick start manual attached to the door of the control cabinet to turn on the battery power and turn on the machine. Follow the instructions to process the alarms related to the initial start-up step by step, select the robot and activate the safety configuration (if any). At this point, the robot uses the T1 (operation mode) action robot, which is connected through the X11 safety loop interface to realize the interaction with safety signals such as external emergency stop safety doors before all modes of action can be used.This is the end of the run-in-operation, so please continue to check back on the run-up defined by KUKA.

(3) [Main Menu] - [Put into Operation] - [Put into Operation Assistant] Enter the Put into Operation Assistant, click the relevant options step by step to operate, and complete the operation.

5. Boot burns the fuse, and the CCU board confirms that there is no problem

Cause: Burning the fuse is usually caused by an electrical short circuit.

Solution: Please disconnect the peripheral wiring and plug of the robot, check it carefully and turn it on again.

It is recommended to check the corresponding fuses according to the operating manual as follows:

(1) Check the grounding. 

(2) Check the power supply. 

6. KSS26012

KSS26012: Confirm that the general servo error ({drive letter} is generally caused by information (KSS26013 general inverter failure ({drive letter}).

Cause: 

(1) Damage to the KPP/KSP or cable connection problems 

(2) A problem with the supply of a low-voltage power supply, or a low-voltage power supply error between the CCU and the KPP/KSP 

(3) Some versions of KPP/KSP firmware issues 

Solution: Confirm the above problems and replace them preventively

7. What are the issues that need to be paid attention to during the external axis configuration process?

It is important to pay attention to the parameters related to the motor and the external axes, as well as the transformation relationships of the coordinate systems. For further details, please refer to the external axis configuration manual.

8. KSS15102

Teach pendant problems, preventive replacement is recommended

9. KSS26013

KSS26013  General inverter failure ({drive}).

Cause:

(1) Damage or connection of KPP/KSP 

(2) Low voltage power supply error between CCU and KPP/KSP 

(3) Some versions of KPP/KSP firmware issues 

Solution: Confirm the above problems and replace them preventively

10. What should be done when the basic check of the robot is overdue?

This prompt indicates that the robot needs to be serviced.

11. KSS15074

KSS15074  Error in drive {device name} security junction, channel {channel number}

Cause: RDC/KPP/KSP/Encoder Line Damage/X11 Wiring Issue.

Solution:

(1) Check if there is a problem with the wiring of the X11. Check whether the power connection between CCUsr and KPPsr/KSPsr is normal. 

(2) Replace the spare parts corresponding to the alarm. 

12. The teach pendant is malfunctioning

If the teach pendant screen is not accurate, please obtain the teach pendant calibration manual, if the teach pendant screen is not touchable/black screen/emergency stop, etc., please try to cross-swap the teach pendant to confirm the failover. Once you are sure that the teach pendant is faulty, contact after-sales processing, bringing your address and a photo of the robot's nameplate.

13. The oil leak from the balancing cylinder.

If there is an oil leak problem in the balance cylinder, please confirm the oil leakage point, and then move it to a specific position according to the manual to record the pressure value. Please call for details

14. Alarm KSS12005

Ballast Resistance Temperature Sensor: Wire disconnection KSS12005

Ballast Resistance Temperature Sensor: Wire disconnection

Causes: (1) Contact problem or wrong plugging on the CCU;  (2) Damaged sensor

Solution: Check the connection or replace the temperature sensor

15. Ethercat communication error alarm

KSS13012、KSS13012 < {Bus identification number} > ECat Stack  Error initializing [ {Reason} {Reason 2} ]

Cause: Analyze problem points in the bus through diagnostics

Solution: Troubleshoot cable connectivity failures or module damage and replace them preventively.

16. The cable of the teach pendant is not in good contact, and the safety input terminal is incorrect  KSS15101

KSS15101 Security Device {Device}: Input {Input} error

Causes: (1) The mode switch and cable of the teach pendant are faulty 

(2) Dual Channel Pass error on CIB 

(3) The SIB of the security interface board is damaged 

Solution: (1) Check to rule out the teach pendant problem

(2) Check the dual-lane connection in the safety wiring 

(3) Troubleshoot the preventive replacement of the CIB board 

17. Oil leakage at A6 axis.

It is recommended to follow these steps to identify the oil spill:

(1) Verify the color of the oil with a white facial tissue, then wipe it clean, run it for a period of actual time and then observe whether there is an oil leak and determine the point of oil leakage. 

(2) Check the body for oil impact marks. 

(3) Make a record of KRCDiag in a timely manner. 

(4) Call the after-sales hotline. 

18. Alarm KSS01133

KSS01133 Maximum transmission torque for axis {axis number}

It is recommended to investigate the following aspects:

(1) Error on the main axis: Driver firmware version problem, overload operation, encoder cable damage, or power supply out of phase. 

(2) External errors: resistance to mechanical systems, overload operation or asymmetrical installation. The encoder cable is damaged 

19. Safe stop (safety device communication error)

KSS13015  <{Bus identification number}> Ethercat Bus-Scan fault.

KSS15002  Security device {device} communication error.

Cause: The bus could not scan the faulty device.

Solution: It is recommended to replace the corresponding spare parts after checking.

The following check steps:

(1) First of all, check whether the 27V power is normal, and check whether the interface pins are abnormal. 

(2) If there is no problem, disconnect the power supply, make sure there is no voltage, and replace the faulty device. 

20. Alarm KSS13018

KSS13018 <{Bus identification number}> ECat Stack  There was an error initializing.

Device: {Faulted device} [{Additional Information}]

Cause: The bus could not scan the faulty device.

Solution: It is recommended to replace the corresponding spare parts after investigation.。

Steps:

(1) First of all, check whether the 27V power is normal, and check whether the interface pins are abnormal. 

(2) If there is no problem, disconnect the power supply, make sure there is no voltage, and replace the faulty device. 

21. RDC communication failure

KSS13018 <{Bus identification number}> ECat Stack  There was an error initializing. 

Device: {Faulted device} [{Additional Information}]

Cause: The bus could not scan the faulty device.

Solution: It is recommended to replace the corresponding spare parts after investigation.

Steps:

(1) First of all, check whether the 27V power is normal, and check whether the interface pins are abnormal. 

(2) If there is no problem, disconnect the power supply, make sure there is no voltage, and replace the faulty device. 

22. How to start the robot auto mode

(1) Make sure that the program traces have been manually tested without problems 

(2) The robot has no associated alarms 

(3) In T1 mode, select the program to be executed, and manually move until the BCO appears 

(4) Switch the mode to AUX, adjust the program rate by about 30% at the same time, enable it and press the forward button, the robot can be automatically started internally, pay attention to the low-speed operation and increase the speed after confirming the safety. 

23. There is an abnormal noise when the robot is running

The first thing to do is to determine where the source of the squeak is. If the reducer makes abnormal noise, first check whether the robot load data is correct, whether the program acceleration is optimized and other software reasons; Then check the reducer itself, such as lubrication status, internal wear, etc. If the motor makes an abnormal noise, most of the time it is that the motor is worn. In addition, if the balance cylinder is damaged, the robot will also have abnormal noise.

24. The bot is not working

It is possible to encounter one of the following situations:

(1) Toggle the main switch of the control cabinet Q1, there is no electricity in the control cabinet, and there is no indicator light. 

(2) Toggle the main switch of the control cabinet Q1, there is electricity in the control cabinet, but it will "trip" after a period of time

(3) The control cabinet can be started, but it ends up as "Could not set up IP address" or "Waitting for cyclic connection" on the teach pendant or external display.

(4) The teach pendant or external display can enter the system, but there is an "alarm", and the robot does not respond and cannot be manually in T1 mode. 

(5) The robot can be manually operated in T1 mode, but cannot be automatically or externally automated. Please confirm the status of your current robot and ask your questions. 

25. What are the causes of robot jitter?

Possible causes are: 

(1) The load data input is incorrect (the input load data is too high or too low, and the difference between the actual load and the actual load is too large, which will cause jitter.)

(2) There are large turns or attitude changes in the robot's trajectory, and excessive acceleration can also cause jitter. 

(3) Some of the few models have incorrect motor default parameters in the project configuration, resulting in a mismatch of motor outputs that cause the robot to jitter. The need to update the bot catalog and reconfigure the bot project can be solved.

(4) The fastening of the foot bolts is not up to standard.

(5) Optimize the robot position to avoid singular and limit bits.

(6) The motor feedback control parameters are incorrect and the configuration file needs to be changed. 

26. Alarm KSS13068

KSS13068 <{Bus instance}> EtherCAT  User {device name} is not connected to the bus.

Solution: If the fault is in the production and running state, you need to check the Ethecat bus components. If it is the first configuration of the project, you need to check the configuration of the project, the connection of the components, and the connection status of the cable plug. Most of the ongoing failures are due to damaged components. Some occasional failures may be caused by electromagnetic interference, please call the after-sales hotline for specific analysis.

It is recommended to replace spare parts after inspection:

(1) Check the device connection cables and plugs. 

(2) Check the power supply and grounding. 

(3) Check the status of each indicator. 

(4) Confirm that there is no short circuit in the upper and lower power supply. 

27. Alarm KSS26005

KSS26005 Encoder failure (position encoder) ({driver}). If it is a fault in the production and running state, you need to check the motor, connecting cables, RDC board and EDS chip. If the project is configured for the first time, you need to check the motor configuration of the project, the channel of the RDC, and the connection status of the cable length plug.

The steps for motor and cable troubleshooting are as follows:

(1) Measure whether the resistance value of the 8/9 pin KTY temperature sensor on the motor side is normal. 

(2) Measure whether the white/brown thermistor wire of the encoder data cable is broken, and check whether the pins are ejected or damaged. 

28. Alarm KSS26095

KSS26095 RDC  The temperature sensor is disconnected ({driver}). If it is a fault in the production and running state, check the motor, connecting cables, and RDC board. If the project is configured for the first time, you need to check the motor configuration of the project, the channel of the RDC, and the connection status of the cable length plug.

The steps for motor and cable troubleshooting are as follows:

(1) Measure whether the resistance value of the 8/9 pin KTY temperature sensor on the motor side is normal. 

(2) Measure whether the white/brown thermistor wire of the encoder data cable is broken, and check whether the pins are ejected or damaged. 

29. Alarm KSS26024

KSS26024  Confirm that the maximum hysteresis error ({drive}) is exceeded.

Cause: Electrical or mechanical reasons, the maximum position lag exceeds the set value.

Solution: If the robot does not have an external axis, then reduce the load and velocity acceleration after checking the electrical connection. If it is a failure of the external axis, it is usually caused by unreasonable mechanical parameter setting, or the unevenness of the mechanical shaft is caused by unstable resistance.

30. Alarm KSS26129

There are several situations in which EMD calibration is not possible:

(1) The zero point probe is mechanically stuck 

(2) The probe is broken 

(3) The probe is not in the calibrated V-groove range 

First, check the status of the following probes:

(1) Manually test whether the zero point probe rebounds smoothly with the help of a screwdriver, and if it is jammed, it is recommended to apply grease and re-zero calibration test. 

(2) Drain the A4 shaft gearbox oil, remove the probe to check whether the probe head is broken, if it is broken, take out the broken probe head, replace the zero probe, and recalibrate the zero test. 

31. Alarm KSS26031  KSS26050

Cause: The power supply module is faulty

Recommended steps:

(1) Check whether the KSP or KPP device status indicator is abnormal 

(2) KRCDiag confirms the firmware version number of the faulty part 

(3) Disconnect the power supply, make sure there is no voltage (after more than 5 minutes), and check whether there is a short circuit in the lower return line cable of the alarm module (replace KPP or KSP if there is no short circuit) 

32. Alarm KSS15101

Security device {box-2}: Input {input} error

Suggestion: Troubleshoot the teach pendant

Note: When replacing another teach pendant, there may be an automatic upgrade or downgrade process for the teach pendant, just keep waiting and no action is required.

33. The system cannot be entered after booting, and the robot cannot be started

Note: Because the smartpad is connected to the KPC through a remote desktop, when the PC system or CCU cannot work properly, it is possible that the smartpad interface cannot be entered.

Solution: The following operational steps are recommended.

(1) Please guide according to the status of the CSP fault lamp at the customer's site, and if the customer's site conditions are met, you can use the monitor to view, and you can quickly determine whether the PC is a hard disk failure or a CCU failure. 

(2) If there is no external monitor condition, check whether the PC fan is running normally, and if the PC fan does not rotate, it is recommended to replace the PC motherboard and motherboard for testing. If the PC fan is running normally, it is recommended to reinstall the system files and replace the hard disk for testing. 

(3) Check whether the memory modules of the motherboard are plugged in and whether the KPC motherboard and hard disk are properly connected. Whether it's because of the dust on the motherboard. 

(4) Conditionally, swap hard disks to check if the robot can enter the system. If you can enter, try to redo the system with the faulty hard drive, if the system fails, you need to replace the hard drive. 

34. Robot zero points are frequently lost

KSS00106 perform a zero correction {axis number}, the zero point needs to be restored. If the fault is in the production and running state, it is recommended to check whether it is caused by an emergency power failure or electrical fault due to a collision, and it is recommended to check the grounding motor, connecting cables, and RDC board of the equipment. If the equipment is the delivery time is due to bumps in transportation.

Suggested inspection steps:

(1) Check the alarm log to confirm whether there is a collision monitoring alarm, and check whether the site is grounded in a safe and standardized manner. 

(2) On-site inspection of each axis cable joint is not loose or virtual. 

(3) Adjust or replace the motor, encoder data line and current axis data acquisition channel (or RDC board), and re-EMD zero calibration test. 

35. The supply voltage phase is missing

KSS26170 Acknowledgment warning: Supply voltage phase missing ({device type}) ({number}).

It is recommended to follow the steps below to check the power supply status of the device:

(1) The multimeter measures the input of the control cabinet to measure whether the three-phase power supply voltage of the X1 plug is missing phase, and if it is out of phase, check the upper power supply. 

(2) In the power-off state, the multimeter checks whether the input/output terminal of the Q1 circuit breaker is on and whether the power cord is falsely connected. 

(3) Check whether the KPP power connector X4 is loose or damaged. 

36. Emergency stop

Please check whether it is a human emergency stop or an automatic abnormal emergency stop

There are several possibilities for automatic abnormal emergency stops:

(1) Check each emergency stop circuit 

(2) Check the teach pendant E-stop button or swap the teach pendant 

(3) Check for teach pendant electromagnetic interference 

(4) Check the teach-in firmware version, the latest V1.11.0

37. The robot shakes

If the robot shakes, it is very likely to cause a safety accident, please stop the robot immediately to check whether the anchor bolts of the machine are tightened and whether the torque value is in accordance with the KUKA standard. For specific standard information, please call the after-sales hotline.

38. The number of revolutions of the fan inside the cabinet is below the alarm limit

KSS12056  The number of revolutions of the fan inside the cabinet is below the alarm limit

Reason: Usually due to the aging of the equipment (the fan is a consumable item), it is recommended to replace it during maintenance.

39. There is no electricity in the control cabinet

Power failures are recommended to check for the following:

(1) Check whether the power supply of Q1 is normal

(2) Check the 27V power module line connection

(3) Switching low-voltage power supply device test

40. Alarm KSS26014

Cause: The power supply module is faulty

Recommended steps:

(1) Check whether the KSP or KPP device status indicator is abnormal 

(2) KRCDiag confirms the firmware version number of the faulty part 

(3) Disconnect the power supply, make sure there is no voltage (after more than 5 minutes), and check whether there is a short circuit in the lower return line cable of the alarm module (replace KPP or KSP if there is no short circuit). 

41. Fixed angle, combined failure of the external axle brake and accompanied by A2A3 axis overcurrent

KSS26158

Acknowledgment Error: Brake Comprehensive Fault ({Device Type}) ({Number})

Cause: The corresponding number motor cable is damaged or not connected

Solution: Make the right connection

42. The 5-axis does not get an effective motor temperature

Cause: The 5-axis encoder cable is faulty or abnormally connected

Recommended steps:

(1) Swap the A5 and A6 motor and encoder cables to determine whether the fault is transferred 

(2) If the fault fails, the motor needs to be replaced, and if the fault does not fail, the encoder cable needs to be replaced 

43. Alarm KSS11013

The connection between the PLC and {name} is broken

Cause:

(1) Misconfiguration of Profinet in the WorkVisual project 

(2) The connection to Profinet is interrupted 

Solution:

(1) Check the project bus configuration 

(2) Check the number of cycles for hardware connections or software 

44. Alarm KSS25007 

EDS not formatted on RDC {component name} (error {internal fault number})

Cause:

(1) RDC is corrupted  (2) EDS is corrupted  (3) EDS is not formatted 

Solution:

(1) Replace the RDC  (2) Format EDS or replace 

45. Robot time cannot be saved (reboot will reset)

Cause: PC motherboard battery failure

Recommended steps:

(1) Power off the controller completely 

(2) Do a good job of electrostatic protection 

(3) Replace the coin cell battery 

46. There is no electricity in the exchanger

Cause: The power supply to the switch is faulty

(1) Check the LED indicator of the CCU board 

(2) Check the voltage on the power side of the exchanger 

47. Alarm KSS27003

Axes {axis position masks} are subject to a brake test

Recommended Actions:

Invoke the brake test program

48. The KR C5 three-tier cabinet cannot enter the system when it is turned on

Note: Because the smartpad is connected to the KPC through a remote desktop, when the PC system or CCU cannot work properly, it is possible that the smartpad interface cannot be entered.

Solution: The following operational steps are recommended.

(1) Please guide according to the status of the CSP fault lamp at the customer's site, and if the customer's site conditions are met, you can use the monitor to view, and you can quickly determine whether the PC is a hard disk failure or a CCU failure. 

(2) If there is no external monitor condition, check whether the PC fan is running normally, and if the PC fan does not rotate, it is recommended to replace the PC motherboard and motherboard for testing. If the PC fan is running normally, it is recommended to reinstall the system files and replace the hard disk for testing. 

(3) Check whether the memory modules of the motherboard are plugged in and whether the KPC motherboard and hard disk are properly connected. Whether it's because of the dust on the motherboard. 

(4) Conditionally, swap hard disks to check if the robot can enter the system. If you can enter, try to redo the system with the faulty hard drive, if the system fails, you need to replace the hard drive. 

49. After the power cord of the control cabinet is plugged in, turn on the green power switch, the green power switch is lit, but there is no response in the control cabinet, no indicator light is on, the PSU 230V/27V module is measured, there is 220V input, but there is no DC 24V output

Operational Recommendations:

(1) Check the power supply status, whether the power supply is normal, and whether the grounding is qualified 

(2) Check the robot cable for damage 

(3) The above two points ensure that new spare parts are not damaged. Replace 27 power modules. 

50. KSS15101 safety input alarm: the safety loop is short-circuited and the alarm is automatic and manual can not be operated, and the safety loop is not short-circuited manually can run automatically

Security Device {Device}: Input {Input} error

Cause: The safety input of the safety device is not working.

Solution:

(1) Determine whether it is caused by incorrect wiring of X11. 

(2) Determine the working status of the SIB board, and replace the SIB board for testing if possible 

51. The A2 axis does not touch anything during operation, and the collision recognition alarm is reported for no reason

Operational Recommendations:

(1) Check the load status of the customer's robot to see if the FLOOR installation robot is incorrectly selected as wall mount or upside down 

(2) Check whether the customer collision recognition is set unreasonably 

(3) Swap motor test 

If it still exists, replace the gearbox

51. RDP sesssion interrupted, RDP is disconnect

Operational Recommendations:

(1) Check the working status of the LED light of the CCU communication port. 

(2) Check the communication network cables. 

(3) Connect to the monitor to view the error message. 

(4) Pair change teach pendant test. 

(5) If the reboot can be eliminated, there is a high probability that the system memory is insufficient, and the system patch package or system can be upgraded.

52. Alarm KSS01073

Set reducer torque {axis number}

Operational Recommendations:

(1) Check whether the robot is damaged by external force 

(2) Check whether the robot is overloaded dynamically and statically 

(3) Reduced velocity and acceleration in the running program 

(4) None of the above will replace the drive and motor 

53. Battery alarm KSS13105

Damaged battery - The load test failed

Cause: Failure caused by the battery not connecting or insufficient battery capacity

Operational Recommendations:

(1) Check the X305 plug 

(2) Battery load test 

(3) Check the battery fuse 

(4) Replace the battery 

54. The 4-axis encoder is faulty

Operation suggestion: whether the interchange encoder cable is transferred, such as transfer, cable failure or RDC side plug failure, if not, motor failure.

55. Error message A6 axis KSS26105 Grounding error

KSS26105  Warning: Grounding '{Device Type} and '{Number} 

Cause:

(1) The motor is damaged 

(2) KPP/KSP is damaged

(3) The motor cable is damaged 

Solution:

(1) Replace the KPP/KSP driver module 

(2) Replace the motor 

(3) Replace the cable 

56. Hardware corruption was found when EDS was written on RDC  KSS25002

KSS25002  Hardware damage (fault {internal fault number}) found when EDS is written on the device {component name} and preventive replacement of the EDS.

57. Unable to power on (no alarm)

It is recommended to follow the steps below for troubleshooting:

(1) Interchange the teach pendant for testing 

(2) Interchange CCUs for testing 

(3) Check whether the configuration in the project is correct 

58. Alarm KSS13106

Rechargeable battery warning - Aging batteries found, but still sufficient

Solution: Preventive replacement

59. Alarm KSS01105

KSS01105  Positioning monitoring {(axis number)}

Cause:

(1) The wrong mechanical parameters were set. 

(2) The reduction ratio is set incorrectly 

(3) If it is the corresponding A2 axis, check the balance cylinder for damage or leakage 

(4) Motor reasons 

(5) Cable connection between motor and encoder 

Solution:

(1) Adjust  $IN_POS_MA[ ]  or  $TIME_POS[ ]

(2) Adjust the reduction ratio 

(3) Replace the balance cylinder 

(4) Preventive motor replacement 

(5) Connect the cables correctly 

60. Alarm KSS00106

KSS00106 perform a zero correction {axis number}, the zero point needs to be restored. If the fault is in the production and running state, it is recommended to check whether it is caused by an emergency power failure or electrical fault due to a collision, and it is recommended to check the grounding motor, connecting cables, and RDC board of the equipment. If the equipment is the delivery time is due to bumps in transportation.

Suggested inspection steps:

(1) Check the alarm log to confirm whether there is a collision monitoring alarm, and check whether the site is grounded in a safe and standardized manner. 

(2) On-site inspection of each axis cable joint is not loose or virtual. 

(3) Adjust or replace the motor, encoder data line and current axis data acquisition channel (or RDC board), and re-EMD zero calibration test. 

61. A1 axis squeak

When there is an abnormal noise, first judge whether there is a accompanying alarm record. Normally, there is a certain amount of friction on the inside of the A1 axis, most likely due to lubrication.

Suggested on-site inspection steps:

(1) Remove the base apron and check for foreign objects or wiring pack friction. 

(2) Remove the manual single axis of the motor, and run the motor dry to check whether there is any abnormal noise. 

(3) Manually rotate the gearbox with the help of the rocker to check whether there is any abnormal noise and jamming. 

(4) Take a video and contact after-sales.

62. EMD calibration is not possible for 4 axis

There are several situations in which EMD calibration is not possible:

(1) The zero point probe is mechanically stuck 

(2) The probe is broken 

(3) The probe is not in the calibrated V-groove range 

First, check the status of the following probes:

(1) Manually test whether the zero point probe rebounds smoothly with the help of a screwdriver, and if it is jammed, it is recommended to apply grease and re-zero calibration test. 

(2) Drain the A4 axis gearbox oil, remove the probe to check whether the probe head is broken, if it is broken, take out the broken probe head, replace the zero probe, and recalibrate the zero test. 

63. The A5 axis has a large clearance and wobble

The delivery of the robot has been strictly inspected, and if there is a large gap or shaking of the body, then the mechanical part has been damaged.

It is recommended to check the following sections:

(1) Check for the presence of the belt (whether it is aged or fractured). 

(2) Check the diagnostic records for collisions. 

(3) Check the payload. 

(4) Check for zeros and deviations. 

(5) Collect diagnostic and trace data and contact after-sales service. 

64. EMD is connected to the robot (not connected on the teach pendant)

If the EMD does not work, please check the following:

(1) Confirm that the EMD is functioning properly and that the probe is shrinking 

(2) Check whether the connected interfaces are normal 

65. Alarm KSS12056

KSS12056  The number of revolutions of the fan inside the cabinet is below the alarm limit

Reason: Usually due to the aging of the equipment (the fan is a consumable item), it is recommended to replace it during maintenance.

66. Alarm KSS26170

KSS26170 Acknowledgment warning: Supply voltage phase missing ({device type}) ({number}).

It is recommended to follow the steps below to check the power supply status of the device:

(1) The multimeter measures the input of the control cabinet to measure whether the three-phase power supply voltage of the X1 plug is out of phase, and if it is out of phase, check the superior power supply. 

(2) In the power-off state, the multimeter checks whether the input/output terminal of the Q1 circuit breaker is on and whether the power cord is falsely connected. 

(3) Check whether the KPP power connector X4 is loose or damaged. 

67. Alarm KSS26230  KSS26155

Cause: The power supply module is faulty

Recommended steps:

(1) Check whether the KSP or KPP device status indicator is abnormal 

(2) KRCDiag confirms the firmware version number of the faulty part 

(3) Disconnect the power supply, make sure there is no voltage (after more than 5 minutes), and check whether there is a short circuit in the lower return line cable of the alarm module (replace KPP or KSP if there is no short circuit). 

68. Alarm KSS26157

KSS26157  Acknowledgment error: Failed to load intermediate loop.

Possible causes of the error:

(1) KKP is damaged 

(2) PLC cancellation signal $DRIVES_OFF

Reason (1): Check the following:

* Check the grounding 

* Check the power supply 

* Check the status of each indicator of the driver module

* Check whether there is a short circuit in the alarm axis cable 

* No short circuit interchangeable KPP check 

Reason (2): Check the PLC output signal $DRIVES_OFF.

69. Alarm KSS27007

KSS27007 The holding torque of the brake {brake number} {axis number} is insufficient. If there is a fault in the production state, check the motor and power supply. If it is a fault in the state of holding brake test, please confirm the position before doing the test. After ruling out the electrical cause, it is recommended to swap the motors to confirm the fault.

70. PC malfunction/power supply is normal/fan is not working

It is recommended to replace the PC with the following steps:

(1) Disconnect the power supply and make sure there is no voltage 

(2) Unplug the PC cable, replace the PC, and make sure that the hard drive needs to be restored to the new PC 

71. The teach pendant shows WAITING FOR CYCLE

Note: Because the smartpad is connected to the KPC through a remote desktop, when the PC system or CCU cannot work properly, it is possible that the smartpad interface cannot be entered.

Solution: The following operational steps are recommended.

(1) Please guide according to the status of the CSP fault lamp at the customer's site, and if the customer's site conditions are met, you can use the monitor to view, and you can quickly determine whether the PC is a hard disk failure or a CCU failure. 

(2) If there is no external monitor condition, check whether the PC fan is running normally, and if the PC fan does not rotate, it is recommended to replace the PC motherboard and motherboard for testing. If the PC fan is running normally, it is recommended to reinstall the system files and replace the hard disk for testing. 

(3) Check whether the memory modules of the motherboard are plugged in and whether the KPC motherboard and hard disk are properly connected. Whether it's because of the dust on the motherboard. 

(4) Conditionally, swap hard disks to check if the robot can enter the system. If you can enter, try to redo the system with the faulty hard drive, if the system fails, you need to replace the hard drive. 

72. The new machine A5 and A6 cannot be calibrated

If the new machine calibrates and calibrates, please try to manually test whether the rebound of the zero probe is smooth with the help of a screwdriver, if it does not move, it is likely that the probe is hardened by the fixed red glue.

The probe replacement procedure is as follows:

(1) Prepare a heat torch, special tools for removing the probe, and red glue 

(2) The zero deviation is checked and the shaft is moved to a position where there will be no oil leakage 

(3) Use a heat torch to heat the probe tip when dismantling 

(4) After installation, smear red glue to reinforce 

73. Alarm KSS26112

Warning: The heat sink temperature is too high ({device type}) ({number}).

Cause:

(1) The external fan is damaged. 

(2) The cooling circuit is dirty. 

(3) There is no payload data or the payload data is incorrect. 

(4) Excessive ambient temperature. 

(5) The drive module is damaged. 

Solution: 

(1) Replace the external fan. 

(2) Clean the cooling circuit. 

(3) Fill in the correct load data. 

(4) Use a cooling device. 

(5) Replace the corresponding drive module. 

74. External security alarm (Error reported at safety input)

KSS15101  Security Device {Device}: Input {Input} error

Cause: The device on the bus could not be scanned

Solution:

(1) Check that all channels of X11 are dual-circuit wiring 

(2) Check that the SIB cable connection is normal 

(3) Check whether the fuse of the SIB board lights up red 

(4) Switching SIB board test 

(5) Check the SmartPad cable, swap test 

75. Alarm KSS15073

Acknowledgment: Error in drive {device name} security node, channel {channel number}

Cause:

(1) The motor's cables are damaged or not connected 

(2) The corresponding drive module is damaged 

Solution: 

(1) The cable is properly connected 

(2) Replace the corresponding module 

76. Alarm KSS15105

Security device {device}: Feedback {feedback} error

Cause:

(1) The SIB is damaged

(2) The US2 power supply contactor is faulty 

(3) X11 wiring error 

Solution:

(1) Replace the SIB board 

(2) Check the US2 power supply contactor 

(3) Exclude X11 wiring 

77. KSS26230 Short circuit in the charging thyristor supply 1

Cause: The power supply module is faulty

Recommended steps:

(1) Check whether the KSP or KPP device status indicator is abnormal 

(2) KRCDiag confirms the firmware version number of the faulty part 

(3) Disconnect the power supply, make sure there is no voltage (after more than 5 minutes), and check whether there is a short circuit in the lower return line cable of the alarm module (replace KPP or KSP if there is no short circuit) 

78. Alarm KSS26010 A6 overload after 60 seconds

Confirm that the current is overloaded after {time} seconds ({drive})

Cause:

The axis exceeds the holding current, is overloaded or jams

Solution:

(1) Confirm that the payload data is correct 

(2) No collisions during operation 

(3) Diagnostic records are kept 

(4) Replace the corresponding motor or gearbox

79. Alarm KSS00404

Security device {box-2}: Input {input} error

Operational Recommendation: Troubleshoot the fault in the exchange teaching device.

Note: When replacing another teach pendant, there may be an automatic upgrade or downgrade process for the teach pendant, just keep waiting and no action is required.

80. Alarm KSS26045

Error: Short circuit in braking resistor ({device type}) ({number})

Cause: The device detected a short circuit at the ballast resistor

Solution: Check the ballast resistors, power supply, and wiring for faults, and eventually replace hardware such as drivers.

81. There is no alarm jitter in the robot

It is recommended to check whether the power cable from the control cabinet to the robot body, and whether the X20 and X30 plugs are connected firmly and in place.

82. KSS12051 Drive box {name of KPP} 

Fan E1 RPM is too low

Drive box {name of KPP}: Fan E1 RPM is too low

Cause: The fan is damaged or the E1 foreign object is stuck in the fan

Solution: Replace the fan

83. KSS26097  The effective motor temperature A1-A6 is not obtained

KSS26097  No effective motor temperature ( {drive} )

Cause:

(1) RDC failure 

(2) The motor encoder is damaged 

(3) Errors in some firmware versions. 

Solution:

(1) If the fault of a single shaft is a failure, there is a high probability that the encoder cable will be damaged 

(2) If it is a failure of the A1-A6 axis, RDC is more likely (please check the firmware version first) 

84. Robot 100% speed, additional axis alarm, alarm code KSS26024

KSS26024  Confirm that the maximum hysteresis error is exceeded ({drive})

Cause:

(1) Motor failure 

(2) The newly configured device positioning tolerance parameter range has changed 

Solution:

(1) Old equipment is faulty, check the motor 

(2) For new equipment, especially external axis failures, priority should be given to checking the reasonableness of motor parameter settings. 

85. Alarm KSS26011

KSS26011  Current overload after {time} seconds ( {drive} )

Cause:

(1) The motor stop current is exceeded for too long 

(2) The plug connection between the KPP/KSP and the motor is incorrect 

(3) Overload operation 

Solution:

(1) Prioritize checking the load 

(2) Check the plug adapter 

(3) Some small machines need to check the holding current parameters 

86. KSS13103  Rechargeable battery or battery fuse damaged (unable to cache), battery damaged (load test failed)

Cause: Failure caused by the battery not connecting or insufficient battery capacity.

Operational Suggestions:

(1) Check the X305 plug 

(1) Battery load test 

(3) Check the battery fuse 

(4) Replace the battery 

87. Alarm KSS26137 / KSS26104

KSS26137  Acknowledgment Error: Overload Error IxT ({Device Type}) ({Number})

KSS26104 Warning: Overload Error IxT ({Device Type}) ({Number})

Cause:

(1) Firmware error for some versions 

(2) Overloaded data runs 

Solution:

(1) Upgrade the firmware 

(2) Replace kpp/ksp

88. IO module failure (no response from input and output).

Solution:

(1) Measure the supply voltage of the IO module 

(2) Check whether there is a fault in the network communication of the network cable 

(3) Check whether the I/O configuration of the robot project is consistent with the actual configuration 

89. Alarm KSS26230 

Fault: Short circuit in the charging thyristor

Cause: The power supply module is faulty

Recommended steps:

(1) Check whether the KSP or KPP device status indicator is abnormal 

(2) Whether the resistance value of the motor and the wireclad cable is normal 

(3) KRCDiag confirms the firmware version number of the faulty part 

(4) Disconnect the power supply, make sure there is no voltage (after more than 5 minutes), and check whether there is a short circuit in the lower return line cable of the alarm module (replace KPP or KSP if there is no short circuit) 

90. Alarm KSS15003

KSS15003 is a confirmation message, and the original message is a KSS15002 security device {device} communication error.

There may be one of the following reasons: 

(1) The FOSE address of the interface board or module is incorrect 

Scenario: WorkVisual manually sets the FOSE address

(2) RDC/CCU/KSP/KPP failure 

Solution: It is recommended to replace the corresponding spare parts after investigation

(3) The network cable between CCU/KSP/KPP is faulty 

Solution: It is recommended to replace the corresponding spare parts after investigation

91. Alarm KSS00073

KSS00073  Short circuit braking activation (This information is incidental to the machine stopping)

Cause: The system has switched to a short-circuit stop state (e.g., by a servo hardware command).

Effect: Short circuit stop (Prevents activation command)

92. How to create a TCP/tool coordinate system? How to establish a base coordinate system using the three-point method?

(1) You need to make a tool in advance. 

(2) Select the 3-point method to make the base

(3) Follow the wizard prompts to confirm three points: 

The first point is the origin of the base coordinate system.

The second point is a point in the positive direction of X, as far away from the origin as possible to be accurate.

The third point is a point in the positive direction of Y, as far away from the origin as possible to be accurate.

93. KSS00276  Robot parameters are not equal to the robot type

Note: First of all, it is necessary to confirm that this alarm is only meaningful if the robot does not have alarms such as "Unable to access RDC" and ".......", because this alarm may be generated when the RDC communication is abnormal.

Cause: The [Robot Type] configured in the control cabinet is inconsistent with the [Robot Type] recorded in the robot itself. 

Principle: The [Robot Type] recorded in the control cabinet is stored in R1Mada$machine.dat. Variable Name: $trafoname[] The [Robot Type] recorded in the robot body is stored in the EDS in the EDC box. Variable Name: $robtrafo[] So when the variable $robtrafo[] is inconsistent with the variable $trafoname[], such an alarm will appear. However, this alarm may also occur when the robot is unable to read $robtrafo[].

Common scenarios: under what circumstances will this alarm occur (principle):

WorkVisual configuration, the catalog with a different voltage was replaced. Changed the robot catalog with Workvisual, e.g. changed the FLG from the full-size FLG to the flip-up CLG. Connect a non-standard robot body to the control cabinet.

To solve the problem, first confirm where the data prevails: if the control cabinet (workvisual) side prevails, then modify $ROBTRAFO[].

The modification method is as follows: Log in to the expert mode on the control cabinet side - Teach pendant operation ---- variable ---- single  name: $TRAFONAME[] to record the current value. Name: $ROBTRAFO[], New Value: Write the recorded TRAFONAME[] data to the area with the new value, and click the setting value. If the robot side prevails, use workvisual to delete the original catalog and add the correct one.

94. The KUKA robot is connected to an external axis motor of the KUKA brand (how to check the real-time speed of the motor?). ）

The running speed of the robot body and the external axis can be monitored by the variable $vel_axis_act[n], the time real, n is 1 to 6 to represent the robot axis of the robot, and n is 7 to 12, which represents the running speed of the external axis of the robot.

95. Guidelines for restoring KUKA system images

First, it is necessary to prepare a KUKA recovery USB drive (KUKA.RecoveryUSB).（(Cat. No. 00-220-397) 

* Open the KUKA.Recovery console (Path: Root directory of USB drive > Recovery > Recovery.exe) 

* Make the required settings in Configuration (1) - Operation Mode

* The partition size and other mirror-related parameters can be viewed via the keymaster settings (2).

* Instructions and help for other network-based mirroring features and special features can be found in Key Tips & Tricks or Help (3).

* Close the console with the help of the key to exit (4).

96. KUKA robots have several types of movement

Manual Slow Run (T1)

Manual Fast Run (T2)

Automatic Operation (AUT)

External Auto Operation (AUT EXT)

97. How to modify the network address of the KUKA robot

(1) Enter the teach pendant and set the user group to expert.

(2) Click put into operation - Network configuration

(3) Network configuration has been saved successfully.

98. How to fill in the load data?

Operating Procedures 

(1) Select the main menu to put > Measurement > tool > tool load data into operation

(2) Enter the tool number in the Tool Number field and confirm with the Continue key

(3) Enter load data: M column: Mass; X, Y, Z columns: Position of the center of gravity relative to the flange; A, B, C columns: Orientation of the main axis of inertia relative to the flange; JX, JY, JZ columns: Moment of inertia (JX is the inertia of a coordinate system about the X axis, which is rotated at an angle with respect to the flange via A, B, and C. By analogy, JY and JZ refer to the inertia around the Y and Z axes.)

(4) Confirm with the Continue key

99. Configuration process for communication and input and output signals

The configuration of input and output is related to the communication protocol you use, please make sure first:

(1) What communication protocol you use to communicate with the PLC or peripherals

(2) Whether the robot is the master or slave 

(3) The manufacturer and model of the module 

(4) What kind of functions need to be realized If you need professional remote or on-site service, you can click to transfer to manual and communicate with our engineers in depth

100. Grounding standards for KUKA robots

Equation potential lines that require a robot and a control cabinet must be present.

Disclaimer: All content is only for learning and communication, if you test the application by yourself, it may lead to unpredictable problems, please bear the risks and consequences caused by the test.

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