June 26, 2019, 06:24:18 PM
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 KSS00404 Safety Stop

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August 18, 2017, 08:57:17 AM
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Good Morning,

I am a newbie to KUKA robots. I have searched for the answers from previous posts and couldn't find a solution. Please help !

I am using-
Robot:KR10R1100 Sixx Compact Agilus, KRC 4
KSS : v8.3.32
Profinet Profisafe Device: v3.2.0
GripperSpotTech : v4.0.6
Work Visual : v4.0.24

After connecting all the emergency stops and external safety devices, I still have one error: 'KSS00404 Safety Stop', and solution is recommended as 'Install MCFB option or internal state of controller will remain in fault state' !

Please suggest some solution. Thank you !

Today at 06:24:18 PM
Reply #1



August 18, 2017, 03:02:05 PM
Reply #1

panic mode

Global Moderator
which safety interface you are using? X11 or profiSafe?

if you are using X11 and connections you made are marked in the image - your wiring job is incomplete...
you cannot pick and choose - all circuits must be complete including external enabling switch. check X11 examples in download section.
1) http://www.robot-forum.com/robotforum/kuka-robot-forum/read-first/
2) if you want reply about robot, post it in forum
3) read 1 and 2

August 24, 2017, 03:50:30 PM
Reply #2


Hello Panic Mode,

Thanks for the suggestion. I have completed the wiring, verified for proper connections on X11, X402 and X403. They are found to be correct. But I still have this error 'KSS00404 Safety Stop - Install MCFB option or controller will remain in fault state'  :mad:! Where and How can I install this MCFB option ?

In the Safety configuration, X11 is active. Safety Configuration is set to: Customer Interface - Automatic, Operator Safety Ack: Push Button.
Profisafe add-on is available in my KRC4 compact, but don't know how to check if it is selected !

Connections X11:

1>2 & 10>11 : E-Stop External (NC)
3>4 & 12>13 : Operator Safety (Shorted with Jumper)
5>6 & 14>15 : Ack (NO Push Button)

7>8 & 16>17 : Safe Op Stop (Shorted with Jumper)
18>19 & 28>29 : Safety Stop 2 (NO Push Button) (There is an error at input 5, if I am using jumper or NC here)
20>21 & 30>31 : Consent Extern 1 and Ext Enable 1 (NO Push Button)
22>23 & 32>33 : Ext Enabling 2 (NO Push Button)

Please help me to get rid of this error  :help:

August 24, 2017, 06:28:30 PM
Reply #3

panic mode

Global Moderator

You are not providing enough info. contact numbers you mention are correct for KRC4 compact X11 but that does not mean that wiring is correct. your acknowledge operator safety is wrong - with that setting you must have NO button wired, not fixed jumpers (controller looking for signal change). Enabling switch circuits must be closed. X402 and X403 are internal connections which you should never touch.

Btw. MCFB is Multiprog... which you don't have. If you want that option, you need to buy it from Kuka or - stop using it. There are many causes (15 or so) for KSS00404, installing MCFB is just one of many possible solution. btw this message is never alone. You may not see any other message but you are not looking hard (look at the logs!).I would suggest to create KRCDiag and send it to Kuka service team.

« Last Edit: August 25, 2017, 12:05:04 PM by panic mode »

August 31, 2017, 12:53:03 PM
Reply #4


The problem is solved !

For anyone who is facing the similar problem, completely wire the safety network including enable 1 and 2. In my case, 'KSS00404 Safety Stop' has nothing to do with MCFB option. It's just the complete and correct wiring of X11.

Thank you panic mode !

December 21, 2017, 08:28:16 AM
Reply #5


Dear Mr.Robbie

I didnt got you what it means enable 1 & 2 .
Can you clearly explain X11 drawing.
I also have simiar problem.


December 21, 2017, 05:04:11 PM
Reply #6


Global Moderator
X11 signals labelled "Enable" are to allow the addition of external "deadman" switches, that work exactly the same as the enable switches on the teach pendant.  These are required in some jurisdictions if more than one person is inside the robot's reach at the same time, when the robot is in T1 or T2.  These enabling signals only work in Teach -- Automatic modes ignore them.
If these external enabling switches are not installed, then these signal pairs must be bypassed using permanent wires.

Today at 06:24:18 PM
Reply #7



December 21, 2017, 05:20:28 PM
Reply #7

panic mode

Global Moderator
something like this:

December 22, 2017, 07:27:40 AM
Reply #8


Dear Panic mode,

Thanks for your valuable information.

Problem solved.

March 20, 2019, 10:00:15 PM
Reply #9


Hi every one,

I am new with the robotics world and hope any one is able to give any kind of support. so I am controlling a kuka through  Siemens fail safe PLC.
I do have the same error showing on the teach pendant "KSS00404 Safety stop" again I am using 1500 Siemens PLC that supports profisafe so I am not using X11 terminal for safety evaluation.
I am not able to job the robot on T1 mode this error shows up right a way !!!! any one has been similar situation PLEASE HELP.


March 20, 2019, 10:37:35 PM
Reply #10

panic mode

Global Moderator
you need to read all messages, KSS00404 is generic one, there should always be others, more specific - because there are quite few (and completely different) things can be the cause.

June 06, 2019, 02:54:50 PM
Reply #11


Hello people,

i have the following errors with the profisafe:

I'm using profisafe/profinet without X11.

What i have to do to fix. The PLC read run the ACK_GL routine but i still have the issue

June 06, 2019, 03:39:37 PM
Reply #12


Global Moderator
You have to establish your ProfiNet and ProfiSafe communications.  Right now, your robot and PLC are not communicating.

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