local stop (QE), unknown operation mode

any blown fuses on ESC board? any cables left unconnected? correct version of board?

when powering off with low batteries, robot looses mastering and sometimes hdd can get corrupt.

hey did you solved the problem? i'm with the same one

i would suggest to simply check if ESC board is powered or not - using multimeter (and doing so properly). it is quick and cheap way to confirm some things before diving in.

well 'quick' may be relative, depending on familiarity with using multimeter. for many techs and maintenance guys out there that is the only tool to troubleshoot electrical problems and many don't seem to have a good hang of it.

background story:

i recall case where couple of techs spent hours troubleshooting something that looked very similar (bunch of safety related messages including QE etc.), they were swapping boards etc. but with no result... so i was called to investigate. i asked them if they checked voltages, they said promptly they did and that is not the problem since the ESC (CI3T) is supplied correctly... so i went with them to what they did.

the very first thing i noticed is that they were probing for voltages with the multimeter positive probe (red) while holding negative one (black) on the cabinet. all voltage checks they did that way. but that is not how circuit receives power and this approach can only helps identify at most 50% of the problems (those related to issue with positive side of the circuit). they neglected to consider possibility that issue could be also on the negative side of the supply...

negative supply wires (0VDC) also arrive to that connector (X1). Contacts 1 and 3 are positive, while 3 and 4 are negative. techs obviously interpreted observed reading of zero volts at 2 and 4 as "correct value"... except, that is not a correct way to measure...

to see if negative terminals are connected, one could keep positive probe on something already confirmed as 24V line, then probe the with black probe.... or simply measure by placing both probes on the relevant terminals of board supply connector.

so i got the hands on meter and sure enough, both negative supply contacts on X1 were floating. traced the problem back to missing center jumper on a terminal strip.

we changed the cable from x11 to esc and the fault is gone, but the cable is from a standard cabinet and we have the extend cabinet.

only difference between the cables is a jumper on the connector x6 - when pull it off jumper the fault is back

sorry for bad english

Are you talking about jumper on X6 between pins 1 and 8?

KUKA has made many variants. Versions exist with different safety board, mode selection switch on teach pendant or on cabinet etc.

Btw. all cables shown on schematics have article number ("W" number)

so for example cable W131736 is KUKA article number 00-131-736.

So make sure to use correct schematics and replacement parts.

In my case same error was solved replacing kps600. I changed before KCP but it didnt help.