KUKA Robot Requesting Mastering, Unable to Perform

    Hello,

    This pertains to:

    • Robot KR 16 R2010, S/N 454935
    • Controller KRC4, S/N 390703
    • Manuf. Year 2018

    Warning messages for workspace monitoring functions deactivated and requests for mastering of A1-A6 populated last night while the equipment was inactive. The drives aren’t activating in manual so we aren’t able to perform the mastering. This could be a result of the safety functions and the robot not knowing it’s position. We are actively troubleshooting. I’m reaching out for your recommendations and expertise. Any help would be much appreciated!!


  • Go to Best Answer

    Workspace monitoring functions deactivated (mastering error) (KSS15054)

    Perform mastering A1 (KSS00106)

    Perform mastering A2 (KSS00106)

    Perform mastering A3 (KSS00106)

    Perform mastering A4 (KSS00106)

    Perform mastering A5 (KSS00106)

    Perform mastering A6 (KSS00106)

    Is that all the messages? None of those messages should prevent the robot from operating in T1 mode.

    Quote from ntbrow01

    The drives aren’t activating in manual so we aren’t able to perform the mastering.

    You need to check your inputs. $DRIVES_OFF might be False, or possibly $MOVE_ENABLE. You could also try Startup Mode.

    Do you have any of the Workspaces configured to stop the robot? If so, you might need to try the Workspace Monitoring Override. That should be under the same menu for setting up the Workspaces.

    This is what we've done so far and some other symptoms:

    All axis lost mastering.

    Won’t let robot move in T1 mode with enabling switch, but still asking for all 6 axis to be mastered. Will not allow us to switch into external mode.

    No programs on robot controller. Tried loading backups, but kept saying the file did not exist.

    Researched error code KSS15054 and found that it could possibly be a faulted 24V power supply.

    Checked all fuses in control cabinet and found no issues.

    Checked X31 RDC cable, in good condition. Cable is stationary so there’s no flex or weak points.

    Researched how to troubleshoot RDC card, went into robot data on controller and found that we have 0 hours of runtime. From what I researched the RDC card should store this data. Possible corrupted RDC card?

    Checked all ground/servo cables on robot and everything is in working condition.

    • Best Answer
    Quote from ntbrow01

    No programs on robot controller. Tried loading backups, but kept saying the file did not exist.

    That is not normal for a situation where the KRC lost Mastering. I think you may have more serious issues.

    Quote from ntbrow01

    Researched how to troubleshoot RDC card, went into robot data on controller and found that we have 0 hours of runtime. From what I researched the RDC card should store this data. Possible corrupted RDC card?

    Two copies of this data should be stored -- one copy inside the KRC hard drive, and one copy on the RDC. If these values do not match during bootup checks, the KRC should throw specific error messages about this.

    One standard issue that can cause the RDC data to be lost is that the KRC loses communication with the RDC. Losing that communication would also cause a Mastering loss as a side effect, and prevent the drives from turning on in any mode. However, this should also cause multiple additional error messages.

    Are you certain there are no other error messages active beyond the Mastering Required messages? I recommend cold booting the KRC, then listing all the messages, before using the Acknowledge button.

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