KRC1 DSE initialization problem

    I'm having a problem with a KRC1 enabling motion. Software version 4.1.6 SP3

    I'm new to Kuka robots but have done some research and read through the manuals.

    This robot has been sitting for a couple months but prior to this startup we were able to enable motion without any errors. I think these errors would be from something like corrupted files during the power off process so I have ordered new batteries and connected an external 24V power source to the battery supply.

    after boot I get a slew of errors like;

    244 - software version incorrect

    271 - robot no. 0 does not correspond to calibration file

    275 - set robot number - program name

    276 - wrong machine data for this robot type

    The DSE initialization message does not go away and the led on the DSE board stays solid green

    I have tried restoring an old archive but it must have been made with corrupted data because it throws

    88 - Corrupted archive:...

    I have tried manually input the calibration number and set the robot name to recover, the robot no error and machine data errors go away but the software version error is still there and the DSE does not initialize.

    Any help with this would be greatly appreciated!

    Lee

  • SkyeFire February 24, 2023 at 2:47 PM

    Approved the thread.
    Quote from lporath

    I think these errors would be from something like corrupted files during the power off process

    This should not happen. Mastering can be lost if the robot powers down incorrectly (most often due to dead batteries), but other data like the robot serial number should not be affected.

    The error messages suggest that either the DSE-RDC communication has been lost, or the RDC card EEPROM has failed.

    Have any of the cables, particularly the small cable with the cylindrical connectors, between the KRC1 and KR been disconnected/reconnected since the robot last operated correctly? That is one of the most common causes of DSE/RDC communication failures. It's easy to accidentally damage pins in those connectors.

    If the EEPROM has failed, the RDC card will have to be replaced.

    Thanks for the reply!

    The cables may have been disconnected, the robot was moved recently. I'll check for pushed in pins etc. should the DSE boot even with incorrect robot name and calibration no. ? I've read that this could cause bootup issues.

    The DSE mostly exists just to handle communication between the motherboard and the RDC. If the DSE-RDC cable is broken, the DSE should be fine, but you'll get those various data errors.

    However, you mentioned a DSE Initialization message, but it's not in the list of messages you posted. Is there also an error that mentions communications between the DSE and RDC? If the robot is posting the data errors (serial number, machine data) without any communication errors, that might point in the direction of the EEPROM having failed. The EEPROMs last a long time, but at this point, any KRC1 in the world is probably at least 30 years old or more.

    Also, is this a KRC1, or a KRC1A? There was a (experimental?) run of KRC1As that did something different with the RDC -- it's been a looong time, but IIRC they eliminated the RDC EEPROM and kept all the data on the hard drive. The KRC2 went back to using the "classic" RDC with EEPROM approach.

    Update,

    After checking and reseating the DSE>RDW connections the DSE was able to boot and I am able to move the robot. I did not see any damage to connectors when investigating but it could be the cable too. I'm going to have a new one made.

    Thanks for the help!

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