I’m new to robotics and recently purchased a kr 150l150sp/2 with a KR C1 controller is is a GM version. I’ve jumped the CC1 as someone else said on this forum. I am now getting a commands inhibited message when I try to jog any ideas?
Can’t move/jog robot KR C1 GM
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Dusty -
July 11, 2022 at 7:04 PM -
Thread is marked as Resolved.
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Well, first hit "Acknowledge All", then list out the messages that don't clear.
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Configuration error I/o driver DN CH 2:device not responding
Configuration error I/o driver DN CH 2; module 10 error
Configuration error I/o driver DN CH 2; module 33 error
Configuration error I/o driver DN CH 2; module 34 error
Configuration error I/o driver DN CH 1:netpower failure
Configuration error I/o driver DN CH 1; slave 15 error
Error on writing, driver:LPDN Ch 1
Performing mastering A1
Performing mastering A2
Performing mastering A3
Performing mastering A4
Performing mastering A5
Performing mastering A6
Error on reading,driver:LPDN Ch2
Error on reading,driver:LPDN Ch1
Emergency stop
Drives contractor off
General motion enable
Error on writing,driver:LPDN Ch2
Seems like I have a mess on my hands.
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Comment out devicenet driver in iosys.ini and half of the messages will go away.select T1 mode, axis specific coordinate system and you should be able to jog and master the robot
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Okay so I would go to iosys.ini find divicenet driver and put // in the beginning of the line? Sorry for being so lost I’m a complete noob here.
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In KRL comment begins with ;
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Your IOSYS.INI should have a section near the top that looks a lot like this:
Code
Display More[DRIVERS] EKX=59,EKXInit,ethKRLXMLld.o ;CNKE2=21,cnke2CPInit,cnke2drv.o ;DNSC6=20,dnsc6Init,dnsc6drv.o ;DNSC5=19,dnsc5Init,dnsc5drv.o ;DNSC4=18,dnsc4Init,dnsc4drv.o ;DNSC3=17,dnsc3Init,dnsc3drv.o ;CNKE1=16,cnke1CPInit,cnke1drv.o ;INTERBUSPCI=15,ibsCPPciInit,ibpcidrv.o ;DSEIO=14,dseIoInit,dseiodrv.o DNSC2=13,dnsc2Init,dnsc2drv.o DNSC1=12,dnsc1Init,dnsc1drv.o ;PBMASL=11,pbmsInit,pfbmsdrv.o ;DEVNET=2,dnInit,dn2drv.o ;INTERBUS=1,ibusInit,ibusdrv.o ;MFC=0,mfcEntry,mfcdrv.o
Any line starting with ; is commented out. The DNSC (and possibly the DEVNET) drivers are the ones causing all the "DN" error messages you have. Commenting those out for now will remove those error messages. However, to connect this robot to any other hardware, you may need to uncomment them and properly configure them, but we can leave that for the future.
The Mastering errors are because your robot has lost Mastering (zero reference) on every axis. This will need to be fixed after you get the robot jogging. Also, your batteries probably need to be replaced, or you'll likely lose Mastering again whenever you shut off the power.
"Drives Contactor Off" is just a status message.
"Motion Enable" needs to be set up. Simplest way to do this, for now, is to go into /STEU/MADA/$MACHINE.DAT and change the $IN value of $MOVE_ENABLE to 1025.
$IN[1025] is a special "always on" input in KRCs, and $MOVE_ENABLE can be linked to it to use the robot in "standalone" mode. GM had it set up to receive an input from an external PLC via the DeviceNet bus.
The E-Stop error suggests that you're missing a CC1 jumper, or you have a sticking relay on the FE208(?) board inside the KRC.
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Awesom thanks guys now all I have left is the estop message. My jumpers for cc1 are as follows 1-3 2-4 5-9 6-10 7-11 8-12 13-14 15-16 17-18 19-20 21-22 23-24 and I don’t have 25-32 hooked to anything.
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That's going to be tougher. I don't have any wiring diagrams in my archives for controllers that old, and it's been more than 20 years since I touched a GM KRC1, so my memory is going to be precise. Still, we can check off the obvious items:
1. You have the robot in T1 mode? And T1 is showing in the bottom row of the pendant?
2. If you press the E-Stop on the pendant, do you get an additional, different message (should be "internal E-Stop", or something like that, IIRC)
3. is the global variable ISOLATE set to TRUE? This one shouldn't cause an E-Stop error, but might as well set it
4. check the FE207 (FE208?) board.
Now, the FE20x boards were the safety relay boards used by the KRC1 series. GM had their own special version of these boards, because GM just has to customize everything. And GM had a few different versions of the FE boards, IIRC. I found an old document that should be close:
The thing to remember is that KUKA used the same relay pattern for each circuit, and each relay had an indicator LED. Generally, to close a safety circuit, two paired relays had to close within ~20ms of each other (green LEDs), and a third NC relay had to open during that same time window (red LED).
You can see in the diagram there's a separate circuit for the internal E-Stop and the external E-Stop, but the relay groups for each should act the same way. So you should be able to use the Internal E-Stop to see how the External relays should behave.
Another thing: if you only get one of the two NO relays, you have a single-channel fault. I ran into this sometimes when unplugging/replugging CC1 -- the pins "wiggling" as they made contact would cause the relays to cross each other up (that ~20ms time window). Later robots had a reset button for this, but I don't think the KRC1s did -- the only way to fix it was to unplug CC1, then re-plug it smoothly and carefully. Or rebooting the controller might do it, since the power restoration would hit all the relays simultaneously.
As these are electromechanical relays, they can age and fail, or simply stick. Ideally, instead of a jumper on CC1 for the E-Stop, wire an actual E-Stop button, and cycle the button. Which relays on the E-Stop circuit move, and which don't, will indicate which wires may be incorrect, or which relays have failed or are stuck. Sometimes, just a firm tap on a stuck relay will free it up.
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Okay so
1. T1 is on on the pendant
2. when I press the estop on the pendant or controller I get a local emergency stop message, after I acknowledge it I have two estop messages. 3. As for global variable ISOLATE I haven’t found it yet.
4. On FE 207 both sets of relays for the estops are green the only ones that aren’t working as should are the 4K relays. On the FE 208 board my 8K relays have a red light, the ECR1 relay is green, ECR2 is green and my 9k relays are green. The diagram you posted shows V13,V17 as estop at the robot pressed one of the 9k relay lights are marked as V13 but I cannot find V17.
Kinda confused about what my next move should be could it be a software problem? Thanks.
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As for global variable ISOLATE I haven’t found it yet.
Might be INISOLATE -- IIRC, it'll be in $CONFIG.DAT somewhere. It's not terribly important right now -- the robot should throw a message if you need it set.
Kinda confused about what my next move should be could it be a software problem? Thanks.
Without an internal wiring diagram that lists out which relay does what, and which pins on CC1 they wire out to, I'm not sure either. I would try KUKA tech support -- give them the serial number of the robot and the cabinet. In the past, they've been pretty good about finding the "as shipped" data for their robots.
As an aside: making a complete hard drive image backup is vital for a robot this old. If the hard drive were to suffer corruption (very likely with an HDD that old), you'd be stuck without either an image backup, or a complete set of original install CDs from KUKA.
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Okay I just ordered the adapter to make the backup. But the guy who sold the robot to me actually found the manual with all of the diagrams. I’ve got every relay on the fe 207 and fe 208 board working as they should.(had to add a few jumpers on the SD4 terminal and add 2 jumpers on my CC1 plug) Everything seems like it should be good but I’m still getting the estop message for whatever reason. Has anyone ever heard of this?
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So I’ve been reading and I think it could be something to do with Ethernet.. there is a cord that runs out of the cabinet and has been cut. Is it possible to have an estop via Ethernet? If so can I make software changes to get rid of it?
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E-Stop should not have anything to do with Ethernet on that generation controller. All safeties were handled over X11/CC1, and non-safe communications were handled over DeviceNet.
What's the full text (including error code and module) of the E-Stop message?
Mmmm.... try looking at /STEU/MADA/$MACHINE.DAT. It's possible that the system input $IMM_STOP might throw a "E-Stop" message if it's not on. There was a time when there were several non-safe FieldBus inputs that had the same names as some of the X11 signals, and could throw the same error messages.
As a side note, while you're in that file, if $T2_ENABLE is set to $IN[1025], and if your KRC1 has T2 available on the key switch, you should probably change $T2_ENABLE to 1026 for the time being. T2 is often more dangerous than useful, and I would disable it unless/until you really need it.
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$IMM_STOP was the culprit. The error code was 1.
Now whenever I try to jog any axis, axis 2 slightly moves to the + side, cuts the drives off and it gives a message. I’ve gotten several different messages:
Positioning monitor A2
Stopped A2
Ackn. Regulator limit exceeded A2
Motor blocked A2
It has range monitoring on axis 1, 2 and 3 which I do not have a cord for could this be the problem?
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Range monitoring... "rails" on each axis tripping some switches? I don't think that's the issue, IIRC those switches were wired to the safety PLC directly instead of into the robot.
No, the error messages indicate that there's something mechanically wrong with A2. Could be the counterbalance, could be the axis is jammed somehow, could be the A2 motor brakes aren't releasing.
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Turns out there is a servo disconnect SD0 that needed to by jumped 1-11 2-21 3-31. My robot is jogging as it should now thanks for all the help!
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Turns out there is a servo disconnect SD0 that needed to by jumped 1-11 2-21 3-31. My robot is jogging as it should now thanks for all the help!
Ah hah! I don't recall running into that on the GM KRC1s I worked with, but I do recall Ford used to demand them. The official reason was that the KRC1 took so long to boot (true) that it gave them lots of trouble every time they had to shut the robot down to enter the cell.
The real reason was that the plants were generally lousy about replacing the batteries, and the KRC1s lose Mastering on all axes if you turn off the main power without the batteries holding enough charge for the controlled shutdown sequence.
So the Servo Disconnect was a safety-rated way to kill power to the servos without shutting off the KRC power.
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Hey Skyefire,
Does GM KRC2s have the reset button on fe207 and fe208 for the relay trio like you mentioned above? I have the same emergency stop message that I believe may have something to do with the cc1 jumper. I can hear the relays click when I wiggle the wires on the cc1. Can you give me some pointers? I am so close to get the robot moving again.
Also, that inisolate variable, does that have to do with isolation mode on a KRC2s?
Thanks
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KRC2? I thought you were using a KRC1?
I don't think the FE20x series boards ever had a reset button. IIRC, that didn't become a feature until the KRC2 began using the ESC board (the reset button was part of the board) as a replacement for everything the FE20x series boards did. If you have the FE boards, you shouldn't have an ESC board.
I thought you did have the robot moving? Your last post says it was jogging.
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