Need help KRC2 ed 2005 safety bypass

vvelikov · August 18, 2016 at 1:51 PM

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!

vvelikov · August 18, 2016 at 4:27 PM

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?

Misha · August 19, 2016 at 8:17 AM

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.

Misha · August 19, 2016 at 8:20 AM

...

Serpantinas · August 19, 2016 at 8:49 AM

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/…01-576x1024.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.

vvelikov · August 19, 2016 at 9:20 AM

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

vvelikov · August 19, 2016 at 5:55 PM

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!

**panic mode** · August 19, 2016 at 6:10 PM

https://www.robot-forum.com/robotforum/man…obots/krc2-x11/

Misha · August 22, 2016 at 7:59 AM

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.

vvelikov · August 22, 2016 at 8:08 AM

Thanks, here is the photo:

Serpantinas · August 22, 2016 at 8:38 AM

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)?

vvelikov · August 22, 2016 at 9:22 AM

Yes, they fit properly - checked that.
Here is what i have as schematic - posted it earlier:

https://www.robot-forum.com/robotforum/kuk…ach=10025;image

https://www.robot-forum.com/robotforum/kuk…ach=10027;image

Serpantinas · August 22, 2016 at 9:55 AM

You should have somthing like this in CD's or on paper: http://www.kuka-robotics.com/res/sps/48ec81…_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.

vvelikov · August 22, 2016 at 1:06 PM

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

robot-cnc · August 22, 2016 at 2:23 PM

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

vvelikov · August 24, 2016 at 2:28 PM

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?

Serpantinas · August 25, 2016 at 7:49 AM

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.

vvelikov · August 26, 2016 at 12:53 PM

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

**panic mode** · August 26, 2016 at 5:42 PM

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

vvelikov · August 26, 2016 at 5:57 PM

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

Need help KRC2 ed 2005 safety bypass

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