KRC4, Kss 8.3.39, SafeOperation 3.2.4
I've set up my Mastering Reference switch, as usual, but whenever I try running MasRef_Main, once the robot gets to the switch, I get 15066, followed about 3sec later by 15065. So far, I've checked:
1. MasRef position in MasRef_User, and in the safety config, both match
2. Both lights on the switch go dark when the robot reaches MasRef position. And when the robot is NOT at MasRef, the lights are on steady.
3. If I monitor the Safety Inputs, I can see both the A and B channels go from 1 to 0 when the robot reaches MasRef position -- the only odd thing is that there's a 2-3sec lag between when the sensor is physically tripped, and when the Inputs display updates
4. If I deliberately trip just the A or B, I can see that channel change state by itself, and generate a single-channel fault
5. Safety Global Config has Mastering Test Input set to "Cabinet", and the sensor is cabled to X42
6. Made sure the MasRef switch is clear for 10 minutes before trying MasRef_Main
I'm a bit stumped. I've re-taught the MasRef position a few times, with the same results. If I deliberately alter the position in MasRef_User without updating the Safety Config MasRef, I get the "Failed to reach Mastering Position" error instead.
When I've encountered this error in the past, it was always either bad wiring, or metallic debris on the MasRef sensor, and the message would op at the beginning of MasRef_Main, not after the robot reached MasRef position.
My final motion in to MasRef position is slow (big, high-inertia end effector), but I've used lower speeds in the past without having this happen.
Everything else in the Safety Config tests out -- my cell perimeter, my safe zones, my tool. I've tested jogging the tool into the zone boundaries and I get the usual "zone violated" messages. The only thing that doesn't work is the MasRef test.
The only other odd thing on this robot is that it will randomly throw error 13007, "SYS-X48 Remote Connection to EtherCat Bus Active". But that doesn't occur at the same time as the MasRef errors -- it just seems to randomly come and go. This robot doesn't have any EtherCat modules added, so the only thing on the SYS-X48 bus are the CIB, SIB-STD, and SIB-EXT.