This forum is new to me, so please let me know if I should do something differently.
I am working on a robot that has lost it's connection to the bus coupler on x44 (KRC4 KSS 8.2.16, KR240 r2500 prime)
The setup was working for years but at some point gave the following errors:
Kss 01034 error writing driver sys-x44
Kss 01033 error on reading sys-x44
Kss 13012 <sys-x44> error during ecat stack initialization( no network response)
Connected to x44 is a Beckhoff EK1100(rev0018), EL1008(rev0018), EL2008(rec0018),EL4002(rev0020)
I checked the power to the Beckhoff, (via x251), this was ok. both coupler and io's are powered. power light on. But connection lights are off.
I checked the cable, did measurements, its not broken.
configuration/ input output/ IO drivers:
ethercat I/O sys-x44, state light is off/grey
reset: -> "driver reset failed"
Under the configuration tab of the io drivers. it shows two items:
'Simu' with an unchecked box in the column installed. (?)
Ethercat I/O showing no checkbox in de column installed. (?)
The Kuka Ethercat manual tells that error Kss13012 is caused either by wrong configuration or connection to the wrong port.
In workvisual (v5.0.10 build0927), I installed the device descriptions files, downloaded the project from the controller. The configuration is matching with the devices installed in correct order, and IO’s are mapped. Ports are 1001, 1002, 1003 and 1004.
I asked Kuka what was wrong. They told me my configuration was correct. Probably a broken device.
From Workvisual through the KLI I was able to connect to the ek1100, el1008 and el2008. But el4002 gave the following error: Error in DTM El4002 2ch Ana. Output 0-10v 12bit , An error has occurred in the master stack.
Assuming the el4002 is broken. I physically removed it from the ek1100 and copied the project in work-visual. Removed everything on x44 and reconfigured and mapped just the ek1100 with el1008 and el2008. When i activated this project, restart/reload files, it gave the same errors as described above. When connecting to the ek1100 from workvisual through the KLI, the connection to the coupler was made, but this time el1008 gave same the ‘error on master stack’ as el4002.
Then i Looked at the device monitor, looking at the x44 master, it tells me:
Actual master state: INVALID STATE VALUE!! (this state was not reported in the manual )
It also shows 253 frames were sent but none were received.
number of found ecat slaves: 0, number of slaves in configuration: 3
When looking at the slaves on x44 via the device monitor it tells me: 'slave not present.'
Looking at device monitor/ ECatIODriver, it says: Bus instance : ‘sys-x44’ => Error (code 3)
All I understand is that somehow the beckhoff is not returning/ responding to what the x44_master is sending.
Even though, to the best of my rather limited/modest knowledge, it is configured and mapped correctly.
Next I replaced the ek1100, remade the configuration with matching device description file for this ek1100, did the mapping, when activated: same errors/ no effect.
I’m running out of ideas as I'm definitely not an seasoned expert on Ethercat.
Does anyone have an idea what could be the problem here and where I could look next?