We have a "new" (purchased from Kuka in the last 6 months, not run more than a few hours) KR 500 MT with a KRC4 controller, mounted on a Gudel rail. The robot has been moveable for a few weeks now, and we have been working on linking I/O to an external PLC and getting the safety system up and running to begin manufacturing with it.
After a project upload, the pendant began to display the following warning (see pic):
"Enabling switch timeout. Release enabling switch and press it again"
This error prevents us from moving the robot even in "Service > Startup Mode", and cannot be confirmed.
- We cold booted the robot - the error still exists after restart
- We switched pendants with another identical robot that we have in the shop that runs normally - the error persists
- We reverted to an older WorkVisual project that we keep around to troubleshoot these kinds of errors - it's a minimal project, no I/O linking, that just integrates the rail. The error persists.
Since we were doing some I/O mapping, a possible guess is that we mapped some high input to a section of the $IN array that is used for deadman switch monitoring? This doesn't make sense, though, as the older project has no such mapping, and the error persists.
Not a lot online about this error that basic search has given me. We have a ticket in with Kuka right now. Any of y'all got ideas?