Help with driver status change

Hello, i need help with a robot, who is changing by itself the driver status - the I on the bottom left of the screen.

System is krc2 ed05, KSS 5.6.10 5.6.12, Safe Robot with SafeOp 2.2.6. The robot is KR150 L110

The robot worked fine until yesterday - it asked for brake test. After it was done there was some errors - please see the attached screen.

The problem we have is after that the robot started to change the driver status the I sign is going from red to green and back by itself.

After we restart the robot, it is ok, can be moved by hand etc. When we execute a program in AUT mode it is starting and after a few movements stops with red I (IO status sign) and it is impossible to be moved even in T1.

To me it looks like a bad connection somewhere, but not sure where to look exactly. We exchanged the KCP panel but the problem i still there.

Anyone faced such situation?

Thank you in advance!

yes, we did cold start.

The message after the breaktest you can see on my first post.

I will try to do it again now.

Thanks!

after another braketest and the same message, i disabled the braketest in motiondrv.ini.

For now it is working ok, hopefully that was the issue.

One correction - the KSS is 5.6.12, not 5.6.10

is that the reason the I (io drives) to change its state from green to red?

i am looking at input 140 (Drives ON) and it is not coming even when the I is green.

At the moment it is changing from green to red in AUT mode without a reason eben when the robot is not moving

as i understand from Automatic external settings Drives on depends on input 140 by default, no?

so where i should look to fix the issue? Any direction?

There are no errors or faults displayed ... thats the reason i struggle to find a solution

Thanks for the help!

that happens just by itself - going on and off in AUT mode

i think the "Safety mode not possible" is caused of the disabling of SafeOp software - currently Safe monitoring is set to false.

And as i said earlier - the robot has been working fine without an issue for more than 6 months.

As per the red/green I - i named it drives on/of indicator as per the manual not sure what exacty it indicates, but usally it is green all the time after drives ON in Aut Ext or Aut or with deadman switch pressed in T1.

there's no PLC connected... Just beckhoff devicenet bus coupler with some in outs.

I just exchanged the ESC board with the same model (working for sure) but the problem is still there

i am still trying to figure out where to look...

changed it as suggested from kuka support.

The idea was that may be a faulty esc board is throwing some errors and causing the robot to stop.

Any idea what may cause that random red/green change of the io state?