ProfiSafe communication error

not hard drive... i was not talking about servo drive configuration editor... when working with KSS8.2 there is no servo drive configuration editor - only newer KSS version have this. so when integrating external axis etc on a KSS8.2 one has to use a workaround - select and manual insert into project one of the drive configuration templates (known as "wagon driver configuration"). check Work visual help on this.

reading messages in order of occurence:
1. KSS00404, common message when safety related issue is present. this is just a catch all type of message, it is not detailed, other messages are meant to provide more info.
2. KSS00203, login as expert, goto menu Home>Config>AutoExtern, change move enable input to 1025 and this will go away.
3. 4. KSS00205 Software limit A2/A3. This does not prevent you from moving robot. If it did, mastering robot would be impossible. This will go away once you can move the robot (Assuming present software limtis are correct)
5. KSS11011, connection to PLC timed out, this will be there until you have connection to PLC. this does not trigger breaking reaction, it does not block motion or program execution.
6. brake test required is normal when SafeOperation is active. does not prevent you from moving robot.
7. KSS15004, I/O error in safe device. Suggests that some (unspecified) safety device has a problem. This message DOES prevent you from moving robot...
8. KSS00001 EStop... messages suggest that issue is related to smartPad EStop but this is not necessarily the case. this may simply be a result of safety error mentioned in previous messages.

This is as far as things can go based on interpretting screenshots or looking at archive. For further diagnostics collect KrcDiag and send it to KUKA. This will contain additional details such as hardware logs etc. Most of things in KrcDiag used for troubleshooting are proprietary and need correct tool/resources to parse. If you like you are welcome to read them too. btw, in KSS8.2 it is recommended to ignore first KrcDiag - just make second one.

I know you are eager to make it work... when dealing with complex issues i like to rule out software. so deploying clean image would be high on my priority list since:
a) this is pretty quick if you have right things at your disposal (USB recovery stick and good backup).
b) this replaces thousands of files and there is no knowing which of them could have been the problem. so replacing the entire image mcleans the slate and gives pretty good confidence that software side is fine (if one has good backup or clean image).
c) no hardware is needed.

If you do not have known good backup image of that robot, create one now (even if possibly suspect) then try restoring image from hidden partition.

if that still does not help, contact KUKA and ask them to prepare link for your KSS+software options.

if the issue still remains, it is likely that problem is in hardware.
you can try checking diagnostics screens and compare results to a known good values or reference. but this is hard and meant for insiders. the best and fastest way to proceed is to simply start swapping parts. this means need to have access for replacement parts or another KRC4. Note: in KRC4 everything is safety rated - smartPad, RDC, KPP, KSP, CCU... so technically anything could be the problem.

so if you have access to another robot you can try swapping parts.
easiest to swap is smartPad. but... read pinned topic READ FIRST on this... smartPad firmware has to match... Normally this upgrade/downgrade is automatic, just let it run and give it some time... but ... that is not the case on KSS8.2. so if the replacement smartPad is not from system also running KSS8.2 the only way to upgrade/downgrade is manually. and that is risky... you can end up with bricked smartPad.

Quote from xlyanyura

1. opened a basic project that was at work .

Doesn't make sense at all.

Go back to your old project located on robot when delivered.