June 17, 2019, 04:58:28 AM
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 Need help KRC2 ed 2005 safety bypass

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August 18, 2016, 11:51:48 AM
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vvelikov


Hello everyone,
i am trying to wake up a 2006 KRC2 KUKA KR100 P_2 2000 ed 2005 with KSS 5.2.9
The robot came without the HDD so i had to install fresh software.
It is starting ok, but gives error external stop pressed and disabled drives (ext)
As the robot is coming from a Ford factory i suppose it is looking for the safety gate etc...
So can anyone share info how can i bypass the safety switch - i am attaching photo of the cabinet and X11 plug.
Don't know where to look :( any help appreciated!

Thanks!
The design is a pleasure

Today at 04:58:28 AM
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August 18, 2016, 02:27:34 PM
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vvelikov


Some photos of the exact errors, and another problem - there should be a key into the switch from manual to auto etc on the KCP but it is missing - can i switch between them without a key?
Is it a key specific to this robot only or it is a kind of universal one?
May be i can rip off the key lock and put a normal switch instead?

August 19, 2016, 06:17:00 AM
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Miho


Hi.
Try this X11. Works for me.
The key is not specific for only this robot. You can also use keys from other kcp...
Regards.

August 19, 2016, 06:20:34 AM
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Miho



August 19, 2016, 06:49:52 AM
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Serpantinas


Wiring Miho gave might work(never had KRC2), but in KRC4 you have to be careful and check what cabinet you have european or north american, cause they have different wiring: http://formeta.org/wp/wp-content/uploads/2014/12/WP_20140926_001-576x1024.jpg (not your controler). And you should have your KRC2 specifications manual where you can find X11 conection and check your wiring onece more just to be sure.

August 19, 2016, 07:20:16 AM
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vvelikov


Thanks! Will give it a try today and reply with the results

August 19, 2016, 03:55:03 PM
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vvelikov


Hello again :)
it seems that this scheme worked - partly... in my plug i have nothing on pins 37 and 40 so i inserted everything except these. I suppose my plug is slightly different that the one Miho used to have...
The screen now shows just the attached image - External stop pressed and mastering of the axis 1-6
I am attaching also the pages for X11 plug i have - i am not an electrician so it is hard for me to understand what is the meaning of it :(
Anyone with an idea what should i use instead of pin 37 to 40 connection?
Is there a need of 24v to any of the pins?

Thanks for the help!


Today at 04:58:28 AM
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August 19, 2016, 04:10:55 PM
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panic mode

Global Moderator
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 22, 2016, 05:59:09 AM
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Miho


I'm pretty sure that you do not need external 24V.
You mean that you do not have pins 37 and 40? Can you take a picture of your plug?
The one I send you works fine with KRC 1-2 Tested it last week.

August 22, 2016, 06:08:21 AM
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vvelikov


Thanks, here is the photo:


August 22, 2016, 06:38:53 AM
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Serpantinas


Does all pins fully in their sockets? I had a problem where not all pins were actually connecting. And does your manuals have some wiring schemes for X11(simillar what panic mode provided)?


August 22, 2016, 07:55:25 AM
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Serpantinas


You should have somthing like this in CD's or on paper: http://www.kuka-robotics.com/res/sps/48ec812b-1b29-4789-8ac2-598aff70abc0_Spez_KR_C2_ed05_en.pdf
but anyways this is 2005 KR C2 edition specs manual and in pg65 there is wiring example for startup, which is what you did, so if everything is connected then I have no ideas. Wait for pros to give some suggestion.

August 22, 2016, 11:06:26 AM
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vvelikov


Waiting for the pros then ...
It is a Safe Robot i think - similar to the one Signum have, may that is the difference?

Today at 04:58:28 AM
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August 22, 2016, 12:23:24 PM
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Robot-CNC


Hi V.

Your socket it has 108 pins, is from a safe robot X11 or similar. I sent you by e-mail a document to help you. Diagram for wiring and X11 socket is different for safe robot than standard robot. I will not share here any document since somebody recently banned me for sharing a public document from Kuka. I couldn't understand that but I was understood by site adiministrator and unbanned . Safe robot has RDC box bigger on the robot backside, ESC card is also bigger than standard and is possible to have some modules Profisafe in controller below drivers, black boxes with red light leds.
Good luck !

Signum
« Last Edit: August 22, 2016, 01:00:47 PM by signum »

August 24, 2016, 12:28:21 PM
Reply #15
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vvelikov


Tried out all the available schemes for this X11 and nothing works - the message "External Emergency stop pressed" still there and i cannot move the robot.

I tried X11 standalone jumper for KRC2, KRC2 ed 2005 etc... cannot find the one for Safe Robot - may be there is the problem and i need to do something else - not only jumpers on X11? May be it is specific for FORD robots?

The installation is fresh windows XP and KSS 5.2.9 - that is all i have

The Safe robot is not installed but not sure if there is a hardware that is messing the things up :(

Any idea?

August 25, 2016, 05:49:23 AM
Reply #16
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Serpantinas


I would still think that you should have manual specified for your controler(if it's safe or not doesn't matter). Do you have CD's? And if no then my best suggestion would be write to KUKA. If their provided(you can always try to ask) example wiring sheme would not work then it's not wiring.

August 26, 2016, 10:53:00 AM
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vvelikov


Yes, i have the manual and these are the pages about X11 - see attached files.
The problem is that i cannot understand where to bridge :(


August 26, 2016, 03:42:39 PM
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panic mode

Global Moderator
Check download section.... there are examples of X11. I also added jumper plug for krc2 x40

August 26, 2016, 03:57:25 PM
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vvelikov


Thanks, will try it! X40 is a bit odd may be i will need to do it inside the box. Will report the result once done ;)

August 28, 2016, 08:23:14 AM
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Robot-CNC


Hi V !

I think first of all you have to be sure that your robot is a safe version. That means a bigger RDC box and more cables to connect between RDC and controller. To my robot there is a cable which connect X40 from RDC to X21.2 on controller,there is also a X41 which connect to X21.1 and X31 to X21 which is for external axis , signal cable controller to RDC X21to X31 then from RDC to 7-th axis servomotor resolver.
If is safe robot I think you should have these two cables X40-X21.2 and X41-X21.2.
If the diagram you attached for controller sockets is like your real KRC2 , is not same with mine.
I only have X11 for standalone use made by diagram I sent you on email.
I am sending you also by email photos with my X11 bridges wiring but will not be easy to fallow each cable being many and close.
If you made X 11 ok is possible for robot, if safe, to need maybe two more cables between RDC and controller.
Check that.

Signum

« Last Edit: August 28, 2016, 08:29:08 AM by signum »

Today at 04:58:28 AM
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September 06, 2016, 04:11:55 PM
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vvelikov


Yes, definitely is a Safe Robot... tried the X40 schematic - still have the same error - External Stop pressed :(

September 06, 2016, 06:57:33 PM
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Robot-CNC


You need the cable for X40 in my opinion.

September 06, 2016, 07:07:15 PM
Reply #23
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panic mode

Global Moderator
so... you did check all emergency stop buttons, right?
what are messages on the KCP?

September 06, 2016, 07:10:53 PM
Reply #24
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vvelikov


Yes, there are no emergency stops anywhere conected.
The exact message is: External emeregency stop pressed.


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