We have a KR5 arc HW with a KRC4. The robot ran fine at our facility (we are the integrator). We shipped the robot and cell to the customers and reassembled. When I arrived at the customers, I double checked all of the connections, everything looked good. Powered on and tried to move the robot and I get General Servo Errors. I never saw any of these errors at my shop. KUKA has an archive and diag but no real concrete answers. There is a long list of things we have tried which include:
- verifying the incoming power is good (Our KRC4 has a transformer.)
- checked all of the cable connections by disconnecting/reconnecting. (Have done this countless times. Verified 7.1, 7.2, 7.3 connectors for the external motors are good.)
- replaced a KSP because it was showing a red error light (Never had a red light at my shop.)
- replaced a KPP because the early error messages shown on the SmartPad indicated issues with power (Never got these messages at my shop.)
- updated the firmware on both KSP and KPP (Never tried this before.)
- replaced the CCU board (then put the original back in) (The replacement sent by KUKA appears to be defective.) (We have had several CCU boards fail in different robots before.)
- replaced the motor and motor cable mentioned in the early error messages (E2) (I never had to replace a motor or motor cable.)
None of this helped.
We do not have any other robots here to borrow known good working parts from. We are beginning to think some of the replacement parts sent are indeed defective but we do not have any way to verify this.
Wrote a basic WoV project that just included the robot and the robot was able to move. (This seems to indicate that the incoming power is good, the KPP is good, and the KSP for the robot motors is good.)
Wrote another WoV project with the robot and E1 and all 7 motors move. (This seems to indicate that the KSP channel used for E1 at least is good.)
Wrote another WoV project with the robot and 3 external motors and the errors appear. (E2 and E3 use the other two channels on the KSP E1 is using.)
Tried swapping cables to the external motors to see if the early errors would follow the cable swap - they didn't.
Talked to KUKA countless times. Currently working with a KUKA tech onsite.
Still no closer to a resolution.
After putting in the 2nd replacement KSP (which is where we are now), upon power up, we immediately get "General servo error (E1)" and (E2), and (E3). We think perhaps the new new KSP did not auto address itself on the eCat bus so we are trying to figure out how to manually set the address.
What is really baffling is that this same robot ran fine at our shop. When it was shipped, it went on an air ride flatbed (we always ship on an air ride trailer either flatbed or enclosed.)
Has anyone else run into these General Servo Errors before and if so, what was your resolution?