Kuka throwing up errors after removing and reconnecting safety relay

    Our KRC2 controller was stuck with an error message for External Estop Pressed which couldnt seem to clear. On checking the wiring for the estop and the connectors behind the button all seemed fine. It was only on manipulating some of the wiring from the estop to the safety relay that occasionally the error would go away allowing the robot to be jogged. On disconnecting the wiring to the safety relay and reattaching, making sure all was firmly in place the relay itself seemed to be more stable in terms of faults however the KCP is now showing errors of 'E-Stops pressed', Safety Circuit for drives not ready' and 'unknown operation mode'.

    The wiring to the relay is as it was, took care to make sure wiring was returned to original, it just seems that something along the way has caused an issue between the safety relay and the controller.

    Any ideas would be welcome! The old trick of a re-boot doesnt do anything to the errors.

    Many Thanks

    What version of KRC2? What safety hardware options?

    The "Unknown Operation Mode" error means that the safety board inside the robot is not receiving any power. This power is usually received through the X11 connector, but there are variants that do it differently. You need to look at the electrical diagrams for your installation to find the specific wires. But I suspect that the loose/bad wiring was in more than just the E-Stop contacts.

    Hm... it's also possible that the loose wires shorted something. Hopefully not inside the robot. You should check the KRC2 interior for blow fuses or breakers.

    Thanks SkyeFire,

    Just checked - V KRC2 ed05

    Running version V5.5.16.

    In terms of safety hardware I have two external e-stops, a sick scanner and a pilz safety eye.

    Forgive me if i am lacking in detail as i have inherited the set-up. I can see a number of fuses on what i assume to be the safety board, mounted on the inside right of the controller. I can also see where the X11 connector feeds in through the bottom. I may have to do some fault finding inside the cabinet for the safety relay along with checking the fuses.

    Good afternoon all, I am having similar issue with my KRC4 during a maintenance shutdown ( I was away at the time) the welders were disconnected while robot was on and reconnected, now the light bar (pilz safety light curtain) keeps disconnecting after 5 mins and won't allow operation any ideas? The robot is a KR 8 R2100-2 arc HW and its a KRC 4 KSS 8.6.7 HF1 HMI 8.6

    Quote from Modifiedbrock

    Good afternoon all, I am having similar issue with my KRC4 during a maintenance shutdown ( I was away at the time) the welders were disconnected while robot was on and reconnected, now the light bar (pilz safety light curtain) keeps disconnecting after 5 mins and won't allow operation any ideas?

    How are the welders connected to the robot? How are the Pilz connected to the robot? What do you mean by "disconnecting"?

    Quote from SkyeFire

    How are the welders connected to the robot? How are the Pilz connected to the robot? What do you mean by "disconnecting"?

    welders are connected through ethernet cable and Pilz light curtain is wired into plc

    it "disconnects" with an orange light flashing and doesn't allow programs to run

    Edited once, last by Modifiedbrock: more information (July 25, 2023 at 2:58 PM).

    Quote from Modifiedbrock

    welders are connected through ethernet cable and Pilz light curtain is wired into plc

    it "disconnects" with an orange light flashing and doesn't allow programs to run

    That would suggest that the welders have nothing to do with the Pilz LCs.

    If the Pilz are connected to the PLC, I'm not sure how the KRC is part of this issue. It sounds like an issue between the PLC and Pilz.

    Thank you Sky I'm awaiting a cable to connect the plc to the computer to have our Robot supplier to investigate, I believe it could be a faulty plc controller as the screen is lighting up but blank.

    Thanks again

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