Cannot jog either of these 2 KUKA KR5 sixx R650 robots

Quote from jfsushible

errors 310, 20, 404, 200, and 203.

Which are? Even after working on KRCs for 30 years, I don't have the error codes memorized.

Providing the actual text of each error message is important for us to be able to help you effectively.

You can change move enable to 1025. this is done an autoexternal configuration and will fix 203 message.

Then you need to wire the safety circuit or at least install jumpers to fake it ...

Login as expert. Open file $machine.dat. Look for $Move_enable and enter desired input number 1025. Be careful there are 2 files $machine.dat. The one in the systems folder should be the correct one.

This info can also be found easily by using forum search with keyword move_enable.

You can also get the info where to find system variables in the sytem variables manual you can download from Kuka portal. I would recommend for any newbie downloading programmers and system integrators manual for your KSS as well.

Fubini

Quote from jfsushible

#310 Akku Voltage below 22V

Batteries.

Quote from jfsushible

#20 External E-stop pressed

Well, either an E-Stop is pressed, or the E-Stop wiring to the X11 port is missing.

Quote from jfsushible

#203 General Motion enable

This is a "soft" input, intended to come from an external source. Already described by others, but in brief:

KRC I/O all passes through two arrays of Boolean Inputs and Outputs. Two of the Input array are dedicated to be Always True/On and Always True/Off

$IN[1025] ; always True

$IN[1026]: always False

In the file /STEU/MADA/$MACHINE.DAT, the system input $MOV_ENABLE can be "linked" to any single signal in the $IN array:

SIGNAL $MOVE_ENABLE $IN[219] ;FAHRFREIGABE GESAMT

Change the number in the [ ] to 1025 to "bypass" Move Enable. This only works for T1, T2, and AUT modes, not EXT.

There is an official way to change move enable signal, by the menu, something like configure - i/o - auto external.

as already stated - you need to wire the safety circuits...

adding image to your post is no different than pasting screenshot or similar into a any office document (Word or Excel). take the image, crop it, copy it (this places is in the computer Clipboard), then navigate back to your post, place cursor where you want image to appear and paste (this transfer image from Clipboard to your post).

you need to wire all safety inputs. the message is complaining about External Emergency Stop. so check the diagrams and previous discussions.

and no - do NOT connects pins 20 & 21to each other - that creates cross-channel fault. you need to keep channel A and channel B separate. connections for external E-Stop need continuity between 1 & 20 for channel A, and between 2 & 21 for channel B.

Quote from jfsushible

The only wiring to it is a jumper from 3-5, a jumper from 4-6, one from 9-13 and one from 10-14. Thanks again to everyone.

none of those make any sense...

look at this part of the diagram and pay attention to arrows.

arrow pointing to the right are TA (test ausgang / test output).

arrows pointing to the left are inputs.

you need to wire device (switch/contact) between

a) TA channel A, and Input Channel A.
b) TA channel B, and Input Channel B.

Specific to the KRC2sr.

The key factor in any safety circuit wiring is that each "device" is dual-channel: A and B. All connections must be A-A and B-B, no crossover. The A and B channels have high-frequency "fingerprint" signals superimposed on the base 24VDC that the safety supervisor circuit (the ESC board in this case) checks to ensure no one has tried to "cheat" by using a single-channel E-Stop button (just for one example).

Also, both the A and B channels must close within a few milliseconds (20ms?) of each other, or the safety supervisor will throw a single-channel fault, and the only way to fix that is to open both contacts and try again. If you're adding jumper wires to a plug to bypass the E-Stop (or any of the other safety circuits, inserting that plug with the power on can produce a single-channel fault. Sometimes you can fix that by unplugging and replugging, but the timing can be tricky. Sometimes you might need to power down, plug in the safety plug, and reboot.

yes, there are different variants of X11 depending on controller type. and of course it is important to use correct documentation. the screenshot in #13 is a short version - only showing the minimum (safety inputs and power) which is needed to get the robot moving.

but the X11 also contain outputs and post #11 shows full pinout of X11 (outputs as well). unfortunately KUKA schematics is quite messy, things are not grouped and it may be hard to read. so i always made my own variants to show both channels side by side and identify TA and inputs.

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