Issue with Robot Not Starting After Gate is Closed – KRC2 KUKA

Quote from Kuka Morbideli

.. connected them to a switch..

What kind of switch ?

Quote from Kuka Morbideli

.. I have to press the RESET button located inside the box on the panel on the right side of the wall (blue switch) for the robot to recognize that the gate is closed..

Which blue button? Which wall? Which box?

We all know what kind of switch, button and panel you have at your wall.

There exist hundreds of different switches, boxes and buttons that can be connected on thousands of different ways.

In your case it seems that they are connected in a way that after closing the door you must confirm the closing of the door. This, in many countries, is a safety requirement.

Quote from Kuka Morbideli

I pulled out two wires from the jumper meant for the safety gate and connected them to a switch.

You must use four wires, and a safety switch with two contacts, safety devices nowadays use dual channel circuits.

Have a look into the schematics of Kuka and connect safety gate switch according to schematic pinout.

Don't 'pullout' wires out of a 'box' without any clue about what you are doing. You can search this forum for x211c, probably you will find some more hints.

Quote from Kuka Morbideli

However, when I close the gate, the robot still refuses to start the program. I have to press the RESET button located inside the box on the panel on the right side of the wall (blue switch) for the robot to recognize that the gate is closed and allow the program to run.

You have created a "single channel fault".

Modern safety circuits require two channels for every safety device. So the Safety gate requires two relays/switches that open and close at the same time. If those two relays are in different states for more than a few milliseconds, this generates a single-channel fault that can only be reset using the "blue button" you mention.

That button is on the ESC board, which contains all the solid-state safety relays for a KRC2 of that era. The board has two relays for the Safety Gate (also 2 for the E-Stop). Both of those relays must be wired, which means 4 wires -- two Test outputs and two safety inputs. Your safety gate needs to have a Safety Rated switch on it, not a simple non-Safe switch. A Safety Rated gate switch will have two wiring channels (4 contacts), and the 4 wires from the X11 must be wired correctly to those two channels.

the connector is maked X211c indicating that this KRC2 is a Daimler/Mercedes variant. so user guarding should be on pins 9-7 and 8-10