Initial setup questions for used GM KR200/KRC1 - can't get drives to engage/jog

    Brand new KUKA user here coming from a FANUC background. Bought an old KR200/KRC1 and can't quite figure out how to get things working. Right now the goal is just to jog the robot around standalone in T1 mode (no PLC connected, just robot and controller). This is a little more complicated than I thought, so a little lost...

    This KRC1 is the GM version with the CC1 plug on it. KRC V4.1.6 SP3, GUI version v3.3.76 B207 (V)KR C1 V3.3 / V4.1.

    Right now when the robot boots up I see a "200 Drives contactor off" error. Any attempt to jog results in a "1376 Active commands inhibited" error. After acknowledging all, the "200 Drives contactor off" message remains. On the status bar, I have a green "S", a red "O" and a gray "R". I have not seen the red "O" turn to a green "I" in anything I've tried so far.

    The CC1 plug has the following pins jumped: 1 to 3, 2 to 4, 5 to 9, 6 to 10, 7 to 11, 8 to 12, 13 to 14, 15 to 16, 21 to 22, 23 to 24. This matches a forum post from here and also matches the schematic for "CC1 Bridge Plug" with the controller.

    On the controller, key is set to T1 mode (confirmed on display of teach pendant). E-stops on controller and teach pendant are not engaged.

    For Configure > I/O > Automatic External INPUT the following is set up:
    Type programno. - PGNO_TYPE = 1
    REFLECT_PROG_NR - REFLECT_PROG_NR = 0
    Bitwidth programno. - PGNO_LENGTH = 8
    First bit programno. - PGNO_FBIT = 33
    Parity bit PGNO_PARITY = 41
    Programno. valid - PGNO_VALID = 42
    Programstart - $EXT_START = 1026
    Move enable - $MOVE_ENABLE = 1025
    Error confirmation - $CONF_MESS = 1026
    Drives off (invers) - $DRIVES_OFF = 1025
    Drives on - $DRIVES_ON = 140
    Activate interface - $I_O_ACT = 1025

    For Configure > I/O > Automatic External OUTPUTS > Start Conditions the following is set up:
    Control Ready - $RC_RDY1 = 137
    Alarm stop active - $ALARM_STOP = 1013
    User safety switch closed - $USER_SAF = 1011
    Drives ready - $PERI_RDY = 1012
    Robot calibrated - $ROB_CAL = 1001
    Interface active - $I_O_ACTCONF = 140
    Error collection - $STOPMESS = 1010
    PGNO_FBIT_REFL - PGNO_FBIT_REFL = 999

    Under Monitor > I/O > Automatic External INPUTS, the current state of the robot is:
    current programno. = 0
    Type programno. = FALSE
    Bitwidth programno. = FALSE
    First bit programno. = FALSE
    Parity bit = FALSE
    Programno. valid = FALSE
    Programstart = FALSE
    Move enable = TRUE
    Error confirmation = FALSE
    Drives off (invers) = TRUE
    Drives on = FALSE
    Activate interface = TRUE

    Under Monitor > I/O > Automatic External OUTPUTS, the current state of the robot is:
    Control ready = FALSE
    Alarm stop active = TRUE
    User safety switch closed = FALSE (this changes when holding deadman switch and I hear relays engage on controller)
    Drives ready = FALSE
    Robot calibrated = TRUE
    Interface active = FALSE
    Error collection = TRUE

    What should I try or change to let the robot turn drives on and jog around?

    Edited once, last by x9tech (October 3, 2014 at 8:35 AM).

    "Drives Contactor Off" isn't an error message, just a status message. Do you have any other messages at all?

    MOVE_ENABLE and DRIVES_OFF would be the first things to check, but it looks like you already have those taken care of. I don't have wiring docs for the CC1 handy, but if there are no error messages, the CC1 would be the first place I'd look. Hm.... this robot should have come with an internal wiring diagram that includes the FE207 and FE208 boards. You should be able to trace out what those boards are doing by checking the red/green status LEDs on each safety relay.

    Check that one of the relays is cycling every time you squeeze the deadman switch -- it's just possible that you have a sticky relay, or a bad deadman.

    Oh, I nearly forgot -- sometimes it was possible to get the GM bots into a "single-channel" fault, where two relays on the FExxx boards that were supposed to always work as a pair got out of sync. The only way to clear that condition was to eliminate the power on the CC1 circuit. That was easiest to do by unplugging the CC1 cable, but one thing that can happen is that unplugging/replugging the CC1 can actually *create* the single-channel fault if you don't make a clean connection. Basically, if you have to "wiggle" the CC1 into place, you can create the single-channel fault by closing one relay before its "twin."

    So far on the FE207 board I see multiple relays turn green on the right side when deadman is engaged, additionally a group of relays on the left side turns green when e-stops are disengaged. Didn't quite understand the schematic for the board when I looked at it last night but may give it another go today.

    There are two red LEDs that never turn green (V37 and the one above it, if I remember correctly, will double check today). I understand there's some sort of a delay timer in place but holding down deadman for 30 seconds never engages or makes anything else click. Any guidance here of what's "supposed to happen" would be excellent.

    Honestly, it's been too many years since I did anything with one of those old robots. I did have to spend a lot of time working out how the relays interact using the wiring diagram. I do recall that red LEDs are bad, and that each safety-channel relay has three relays -- one that's supposed to open, and two that are supposed to close, when the channel is closed properly. There's little timing-delay cross-connects between those three relays such that, if they don't actuate within some very small fraction of a second from each other, they lock up in a single-channel state -- it's a safety standards requirement.

    But, yes, from what I recall, there should be at least one relay that opens/closes instantaneously with the deadman, followed by another set (and the big K1 relay) once the deadman has been held long enough.

    In the wiring diagrams, start at the coil for the K1 relay and work back. The LEDs should make it fairly easy to locate which relay in the chain is not actuating properly, once you puzzle out the diagram style.

    Good news! Before I powered it up this morning to take pictures, I took the cover off each relay and manually exercised them on the FE207 board. After that, the robot fired right up and jogged for me, no problem.

    So it looks like it all may have come down to a sticky relay on the safety board.

    This may have been the robot's way of testing me for initiation into KUKA world...

    Are you using AUT or EXT mode? There are differences between these two Automatic modes that are important.

    What model controller is this? What version of KSS is it running?

    Do you mean that the robot runs fine in automatic, but you cannot get Motors on in T1 or T2? What error messages are present in T1/T2?

    Quote from mreale


    I have the same problem.
    Changed MFC, still remain the failure.
    Changed PM6-600, still remain the failure.

    This is only in T1 and T2 mode. In AUTO mode works fine.

    Found some solution?

    Thanks.

    LOL, I can jog and run program in T1/T2 mode, but not AUT mode...maybe we can help each other. :grinning_squinting_face:

    The Robot is KR 125 GM Std./ KRC1 / KSS Ver 4.1
    This model have three position, T1, T2 and AUTO. The Robot is working standalone, without PLC.
    In AUTO Mode works fine.

    Here is a Safety Board FE207 Drawing.
    https://drive.google.com/open?id=0B7Vc0…xbjg&authuser=0

    If I push relays 5K1 and 5K2 by hand , and press de dead man in KCP, I can JOG the robot.
    I believe that this failure is due to a problem of fake electrical contact, because sometimes 5K1 and 5k2 get connected.
    Also I measured a tension in relays coil, and there is 3V instead of 24V.

    what's the setting of $gm_wo_plc,
    and

    Ext_start
    Move_enable
    Conf_mess
    Drives_on
    Drives_off
    Safegate_op
    Imm_stop
    T2_enable

    in mada/$machine.dat?

    SIGNAL $EXT_START $IN[178] ;EXTERNER START
    SIGNAL $MOVE_ENABLE $IN[85]
    SIGNAL $CONF_MESS $IN[183]
    SIGNAL $DRIVES_ON $IN[1025] ;ANTRIEBE EIN
    SIGNAL $DRIVES_OFF $IN[85] ;ANTRIEBE ENABLE
    SIGNAL $SAFEGATE_OP $IN[1025] ;SAFETY GATE ON PATH STOP
    SIGNAL $IMM_STOP $IN[1025] ;NOT-AUS VON DER SPS
    SIGNAL $T2_ENABLE $IN[1025] ;SAFETY-SPEED

    Quote from x9tech


    Ucol, did you ever find the issue?


    Sent from my using Tapatalk

    here you are:

    SIGNAL $EXT_START $IN[66] ;EXTERNER START
    SIGNAL $MOVE_ENABLE $IN[65] ;FAHRFREIGABE GESAMT

    SIGNAL $CONF_MESS $IN[1025] ;EXTERNE QUITTUNG

    SIGNAL $DRIVES_ON $IN[65] ;ANTRIEBE EIN
    SIGNAL $DRIVES_OFF $IN[1025] ;ANTRIEBE ENABLE

    SIGNAL $SAFEGATE_OP $IN[1025] ;SAFETY GATE ON PATH STOP
    SIGNAL $IMM_STOP $IN[1025] ;NOT-AUS VON DER SPS
    SIGNAL $T2_ENABLE $IN[1025] ;SAFETY-SPEED

    !!!WARNING: these setting will disable some safety hardward!!!
    Note: in 65 and in 66 is on my DeviceNet IO module connect to X801 on the MFC card.

    and here's the operation process:

    1. in T2 mode, select the program you want to run
    you can test run the program in T2 mode by hold the dead man enable switch and step forward button.
    2. turn to AUT/EXT (on my GM C1, there's only 3 modes AUT/EXT, T1, T2)
    3. follow the message.
    4. hold drive on button until drives ready indicator turn green.
    5. now you can push step forward button OR switch connected to input 66 to run the program automatically.

    Edited once, last by ucol (April 2, 2015 at 9:59 PM).

Advertising from our partners