Greetings. 
My name is Alberto, I'm from Spain and I'm 21. I'm a fellow at a company in my area. I have studied automation and industrial robotics at a local institute.
Now, in my work, I have been put in charge of a Kuka Robot, supposedly a KR C1.
In this post I will be writing my doubts and the process that I am carrying out.
Thanks in advance to everyone who reads my post and to those who can help me with their knowledge.
First, you appear to have a connection failure to E1. Does this robot even have an E1 axis?
Second, the Mastering messages for all axes suggest that, at minimum, your batteries are dead and require replacement.
What is this robot's history? Is it a second-hand robot that was recently purchased? Or has it been in use in this facility more recently? Is this a "stock" KRC, or a customized version (VW, Audi, GM, etc)?
Variable $EX_AX_NUM in /R1/MADA/$MACHINE.DAT needs to be set to 0.
For the E-Stop, you need to determine what safety interface your KRC has, and what (if anything) is wired into it.
I don't know what the "non-prepared" error is -- post the actual error code number.
The SoftPLC is something custom that was added to that controller in the past. Without specific detailed knowledge of its configuration, I can't help with it.
...what? If the error message appears without a code, then it's not a KUKA system error. It almost has to be sourcing from one of the custom software items (possibly the SoftPLC) in the robot. I was assuming that the "perform adjustment Axis xxx" error messages were badly translated Mastering Required messages.
This... changes quite a bit. Unfortunately, simply eliminating the SoftPLC does not remove anything in the Level 0 or Level 1 interpreters that may depend on the SoftPLC. There's no simple way to address this, short of perhaps doing a complete ground-up clean install of a stock version of KSS. But if this KRC also has customized hardware (like the VW-specific models), then there are issues simply installing "stock" KSS.
KUKA Ibéria S.A.U. College
Phone: +34 93 81 42-353
college@kukarob.es
Well, that simplifies things a bit. You definitely need to re-master all the axes, and your E-Stop error is definitely coming from your X11 interface (assuming this is a standard KRC1, and has not had any hardware customizations).
Do you have the internal wiring schematics for the controller? It should have them inside the cabinet, but I've noticed that many second-hand robots tend to have lost them. If not, I believe the Manuals sub-forum has wiring diagrams for the standard X11 interface. You will need a compatible Harting connector and pins to build an interface from. The X11 interface is designed entirely around "dry" contacts for relays -- you can substitute a simple jumper wire to bypass a particular safety circuit. However, keep in mind that any bypassed safety represents a serious potential safety risk.
[size=2]maybe...
for e-stop message i would check drawings. are you sure that safety interface is wired correctly and operational? what is the safety interface? (depends on version of controller).
messages about mastering are telling that robot needs to be mastered. i would fist check if there is communication with RDC and if mastering loss coincides with powering down.[/size]
