First time posting in here and recent uni graduate so I hope not to get too much of a grilling for what could be a very simple fix for the right person with the right knowledge
We have an old KRC1 robot that we are trying to use in a development project. It’s a KR125L90-2, serial number 779002, V4.1.7 SP08. We have another of these setups that I have working perfectly well but cannot get this one to work.
Currently, we are able to run it in T1 and T2 with the enabling switch held down on the pendant after giving it $DRIVES_OFF == TRUE, $MOVE_ENA == TRUE, momentary drives on for the recommended time and pulsing reset faults. As I say, currently totally able to run the robot in T1 and T2, however, I cannot remove the “Operator Safety / Gate Open” message from the pendant in AUT_EXT. Also, in T1/T2 and with the deadmen held, I can get $OUT1011 to energise, which is linked to $USER_SAF, but in AUT_EXT I cannot for the same reason. The strange thing is is that with the guard door closed and the guard safety energised I can see the safety relays within the KRC clicking across to their safe position (the same position as in T1/T2 with the deadman in) but cannot remove this operator safety message.
I have been through every connection of the guard safety and cannot see a problem and both channels of the dual channel safety work correctly in our panel, having ~26v come out of the robot on X11.7 and returned through the guard contactors to X11.8, and the same with X11.25 and X11.26. To remove all doubt, I’ve then linked out the guard safety lines at the control panel end of the X11 cable to try and remove the error message just to eliminate the cause of the problem being in the control panel for the machine. I can also independently remove each channel of the guard safety on X11.7-8 and X11.25-26 and see the two relays (KK5 and K6) energise and I know that they work because (presumably) if they didn't I wouldn't be able to move the robot in T1/T2? That still hasn’t removed the message so I’ve then got a known-good X11 service jumper plug and attached it to the robot and it still doesn’t remove the operator safety / gate open error (see 081653.jpg). I know this is a known good X11 service plug as the other working robot cell will function in AUT EXT with it.
Also attached is the states of the safety relay board (165129.jpg) whilst having the X11 service jumper and AUT_EXT key switch position selected. The auto relays are energised and the user safe relays are also energised.
I’m quite stuck on this now and have been for a few days, is there anything that I’m missing in the software in machine.dat or similar? I don't believe there is as the $SAFEGATE_OP is set to $IN[1025]. I've tried:
- Swapping the FE201 safety board with the known good robot
- Swapping the FE201 safety board with a spare we had laying around (Unknown whether this actually works)
- Swapping the X921 cable from the known good robot
- Swapping the X923 cable from the known good robot
- Taking the X11 connector apart from the bulkhead at the base of the cabinet and checking all the contacts are made (However I'm fairly sure that this isn't the problem as the guard relays on the FE201 board are energised when the guard safety relay is made good).
Thanks for any assistance anyone can give