Posts by Stipe Sutalo
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Hello to everyone,
This morning, after power loss in our facility, we turned on everything and after some 10-15 minutes, one of our robots stopped working and we got next messages:
106 Perform mastering A1
106 Perform mastering A2
106 Perform mastering A3
106 Perform mastering A4
106 Perform mastering A5
106 Perform mastering A6
102 Encoder cable failure A1
102 Encoder cable failure A2
102 Encoder cable failure A3
102 Encoder cable failure A4
102 Encoder cable failure A5
102 Encoder cable failure A6
In manual I found this description of 102 error message:
102 Message text ENCODER CABLE FAILURE **
Cause -- Cable defective (e.g. loose connection).
-- RDW defective.
-- Encoder defective.
Monitor -- Cyclic.
Effect -- Maximum braking (dynamic braking).
-- Low signal at “$ALARM_STOP” output.
-- All active commands inhibited.
Remedy -- Check encoder cable.
-- Check motor, resolver.
-- Possibly replace RDW
We changed RDC card and connecting cable X21-X31 but we have same error message. Also we changed connector on X31 side, where cable X21-X31 is pluged in, but without success.I hope everything is understandable. Thank you in advance!
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Hello to all,
romany4 did you find solution for your problem?
I have same problem. We changed cable and RDW card and we have same thing on all axis.
panic mode do you have some advice what to do?
Thank you in advance!
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Each of the three robots communicates with three encoders that tell what the speed of the conveyor is due to the synchronization between the robot and the conveyors.
When we get an Ethercat fault the complete line is stopped and production can be restarted when the robot is without the specified error.
I just inspected the grounding on all the robots and at two places I found grounding cables that were not tight enough.
One of these cables was on the RDC box (this is the robot that had the error: KSS13016 <ECAR-CTRLBUS> missing reception of network frames [Frame Response Error [Limit = 5]]), and the other ground cable was directly connected for conveyor.
I am pretty sure now that grounding was problem but we will see.
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Hi panic mode and thank you for your fast reply.
The failures are not simultaneous among robots. As example we had KSS13016 on one of our robots at Monday and at Tuesday we got KSS13020 at different robot.
This morning I checked all RDC connections (X21-X31) and all of them have rubber ring in good condition and it seems that all connections are sufficiently tight.
I collected KRCDiags from robots and I will send it to KUKA support.
Our big problem here is when those faults occur, we can't start production until we restart KUKA electrical cabinet. After we turn off KUKA electrical cabinet whole facility goes at emergency stop state until PLC controller is connected with that KUKA robot we turned off. We need at least 15-20 min to start production again. Is it possible to reset this error messages without having to turn off KUKA electrical cabinet?
Thank you in advance!
Best regards
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Hello everyone,
In 2017, three KUKA KRC4 robots for the transport of aluminum rims were installed in our plant.
Last year, errors KSS13008, KSS13016, KSS13020 started to appear on all three robots. After contacting KUKA support I was told to replace all the cables inside the KUKA electrical cabinet, KPP and KSP modules (it was pointless for me to change the modules as the error rarely occurred).
We haven't had any problems with the errors above for the past 10 months, but the errors have started to recur in the past month.
In attachments are three images with errors that occur on three different robots. All robots are on the same network, and they are connected to the main PLC controller via Ethernet switches (Scalance - Profinet).
The figure in attachment also shows the network topology for the part of the plant where the problem occurs.
I hope someone can help me.