Posts by bakerhesseldenz

Robot Information:

Kuka KR210 S C2 FLR ZH210

Serial No. 807471

Manufacture Date: 2003

Draw. No. 394.016

Controller information:

(V)KR C2

Serial No. 22589

Art. No. 001 150 04

Manufacture Date: 2003

I'm currently experiencing the following error messages that are keeping the robot from operating.

1. Failure in ESC Safety Loop / External Emergency Stop Pressed

2. General Error 2 : Hardware Error in Node 1

3. General Error 3: PICB (don't know what this means)

4. Output Error 4: help contact error / ESC Diag R Help Cont

I have replaced the following components with new ..

PC Mother Board

ESC Board

KPS 600/20 ESC Servo Drive controller

DSE-ISB board

KVGA Board

I know some of these components have nothing to do with the safety circuit, but I included them in the list anyway.

I have checked out the Teach Pendant on another machine and it is fine.

I have checked and rechecked the X11 jumper plug a dozen or more times, and it is wired correctly.

I do not have an external safety stop, and am at my wits end at this point as to how to get this message to go away. I have replaced everything in the safety circuit and it persists. Does anyone have any thoughts as to what could be causing this? At this point it is costing me a lot of money to have this robot inoperable, so any constructive insights would be greatly appreciated.

There are a few interesting things about this robot that may or may not be causing the issue. The robot appears to have been upgraded at some point ... or partially upgraded. The ESC Board is the kind that is commonly found on ed05 controllers ... not on a 2003 KRC2 controller. The PC is running Windows 95 and not Windows XP ...

Thanks for your time and consideration.

Scott

Hi,

I'm still working on getting my machine running. Specs are below. The machine starts up fine now ... the motherboard has been replaced and the ESC card has been replaced. Replacing the ESC Card seems to have solved the problem I was having with the External Safety Switch being tripped when I don't have one. Also, the Operation Mode is now properly displayed on the KCP.

So now the problem is ... the KCP seems to be frozen. None of the buttons work. If I turn the operation mode switch from T1 to T2 the screen does not change ... still says T1. If I press the configure button to select the user group, nothing happens.

I had this happen a few times before I replaced the ESC Card, but I could always fix it by restarting the machine. This does not seem to be working now.

KUKA KR210 circa. 2003

KRC2 controller (not edition 5)

Thanks in advance for your thoughts.

Quote from SkyeFire

No... you still didn't identify the board model number, or the KRC version (I can guess that it's a ed2005, given that it has what looks like a Ci3/ESC board), or the relay states, or the status LEDs on the board.

The attached PDFs have the closest matches (not perfect) to what you've shown. They include the details on which connectors, relays, and fuses on the board are part of which safety circuit. Hopefully they'll help some.

Hi again. It is not an ed2005 ... mine was built in 2003. Those PDFs are helpful, thanks.

One strange thing I accidentally discovered yesterday ... I unplugged the power plug (A1/X1) to check if there was power going to that board (It was fine), but when I plugged it back in the ESC board made a click sound. Following that, the red blinking lights went away on the servo drives, and the teach pendant was now allowing me to do more. I still can't jog the robot ... but I do think that has something to do with the Operating Mode switch on the front of the controller ... or the wiring to and from it. The pendant still is not recognizing the mode the switch is in ... Just shows a "?" where "T1" should be.

Quote from SkyeFire

Details matter. Just grabbing a semi-random connector with a fuzzy photo gives us nothing to work with. That relay layout doesn't completely match any board I'm familiar with, so I can't make good guesses from that.

What is the label on the board? What is the label on that cable? What is the actual version of this KRC? Do you have the schematic drawings for this particular KRC? There were a large number of variants, and the connectors and pinouts changed. Are there more boards with similar relays elsewhere in the cabinet?

This, for example, is what a typical CI3 board looks like:

I'm sure you can see the family resemblance, but also multiple differences. None of the CI3 boards I did a quick lookup on in my archives looks like yours. Without something like an actual part number for that board, my only hope of finding a match would be to trawl through my archives looking at every photo. And I have over 100GB of archives. Supporting the forum is something I do in my spare time. Do you understand why the people trying to help you are getting a bit annoyed?

OK. Sorry about that. My post and follow up comments did answer all that though. I apologize for wasting everyones time.

Quote from panic mode

Read schematics. As i recall all four are used. You should measure 24V (or 27V) across two pairs if contacts

Yes, I did that. I'm a furniture designer, not an electrical engineer. I don't have the faintest idea what I am looking at. That is pretty why I am here asking for help, not just to waste everyones time.

I'm starting to get the idea that beginners aren't very welcome here.

Quote from Event Robotics

If you stand in front of the cabinet, its the pcb on the right side.

Got it. Thanks! So I want to check to see if the board is getting power. The white plug, labeled A1/X1, with four black wires going into it is (I assume) the power supply to this board.

Can you tell me how to check for power? I assume I can poke the two test leads into two of the four holes in the plug. Can you tell me which ones I should use?

Quote from SkyeFire

Unlikely -- the internal and external E-Stops have separate messages.

The fact that you have both the internal and external E-Stop messages, as well as Unkown Operation Mode (scroll up the message window), indicates that the safety board is not receiving power.

That makes sense.

Which board is the safety board? Is it inside the PC, or inside the main controller box?

Based on that diagram, my X11 plug looks like it is wired correctly. Could there be a problem with the emergency stop that is located on the front of the controller? The controller was slightly damaged during shipping ... the top of the emergency stop switch was broken off ( I glued it back on). The button seems to function properly (mechanically) ... push it in and it stay, turn and it pops out ...

Could this switch need replacing?

I may need a translation. Are you saying that both problems could be the result of incorrectly wired jumpers in the X11 plug?

If yes. I have the X11 plug in front of me .... Can anyone tell me what holes the jumper wires should be plugged into to get this E-Stop message to go away? And what will solve the operating mode problem?

Hi All,

I'm running a KUKA KR210 with a KRC2 controller.

I solved the problems I was having a few weeks ago by replacing the motherboard. Now everything boots up as it should but I can not jog the robot, or master it, because I am getting a message that an emergency stop button is pressed.

QUESTION 1: My assumption is that something in the X11 plug is not jumped properly ... which is telling it the E Switch is pressed when it isn't. Am I assuming correctly?

On the teach pendant screen ... at the bottom ... to the right of the Ackn. button ... there is a little question mark. I think this box is supposed to show the mode the controller is in ... T1, T2, AUTO, ext. I got a message yesterday that I needed to be in T1 mode to perform a certain task ... even though it was already in T1 mode.

QUESTION 2: Why is this showing a question mark? Is it possible that the mode switch needs to be replaced? Are there any other reasons why this would happen?

I've included a screen shot of the pendant below...

Thanks again!!

I've managed to get the PC running on my KUKA KR210 / KRC2 robot arm. The fan and the hard drive are running now ... when I jump the power up pins on the motherboard. However, the teach pendant is still not turning on.

A friend nearby has a KRC2 controlled robot as well. Can I use his KCP to help diagnose whether mine is faulty? If I plug his pendant in to my controller will this create issues?

Quote from SkyeFire

Did you check the voltage on X961, as Panic already advised?

The KRC uses what is basically a typical PC motherboard, albeit one that is built to heftier industrial standards than your typical home PC.

I don't have a print for the KRC2 motherboards, but this is a fairly typical example:

https://electronics.stackexchange.com/questions/3506…oard-pwr-switch

Hi,

Yes, I have power to the X961. And the PC power supply has been replaced.

Quote from DannyDJ

Which motherboard is inside PC? Or you have maybe a sticker on the PC which says KRC2ed05 or just KRC2? On KRC2 i think it is PWR_ON sign or something like that, and when you short 2 jumpers it should turn on the PC.

Hi Danny. I am running an early KRC2 ... not edition 5. It has a SOYO SY-7vBA133k motherboard. I found a manual for the motherboard, but can not find mention of the Start up pins.

Is there a secret to uploading photos? The drag and drop thing is not working .

Hi, I'm going to upload a few images, if you see the pins for the power up button let me know. In the meantime I will try to find a manual for the MB ... so far I'm not having much luck.

Also ... what is an OIN Header? Can't find anything about that on the net.

Thanks.

HI, Thanks for the info.

It seems that the PC is not powering up at all ... the fan is not running. The KCP is not lighting up because the PC is not starting. The power supply is new (used) and the little silver battery is new (new new :-)) I'd like to try jumping the POWER UP pins next, but have a couple questions ....

1. First of all ... what are they, and where are they?

2. Do I perform this task with the controller turned on or off? In other words, do I jump the the power up pins and then turn it on, or do I jump the power up pins after it is turned on?

If I can get the KCP to light up, then I can deal with the BIOS thing.

Thanks again for your help,

Scott

Hello,

I am having trouble getting a KR210 up and running. The controller powers on and the fans operate. I have lots of blinking lights inside, so there is definitely power to the unit. Main issue I have right now is that the PC / CPU will not turn on ... and the Teach Pendant is not turning on.

I have replaced the power supply to the PC ... so I do not think that is the issue.

The fan on the pc is not running, so for some reason the pc is either not getting power, or it is just not booting up and turning on automatically like it is supposed to.

1. Is there an easy way to check if there is in fact power going to the PC?

2. The servo drives have green and red lights ... they are blinking ... what does this mean?

I'm not really sure where to start. The local integration "experts" seem to be learning while they work on my robot at $130 an hour, so I'd like to see if I can diagnose the issue before I call them back again.

Thanks in advance for the help.

Scott

Hi all,

I am in the process of setting up a Kuka KR210 at my business. I got everything up and running yesterday ... almost ... except the CPU, which apparently has a bad power supply. A New one is on order.

My main question involves a few things I need to do right after startup. I know how to use the mastering tool, so I'm good with that. Firstly, I am going to want to set up parameters for Axis 1. My robot is installed in a place where if it rotates all the way around it will probably take out the wall behind it. How do I set stops so that the robot will only swivel to a certain point? I can't figure out how to word an internet search for this answer ... so here I am.

The new power supply should arrive Monday, so after that is fixed I'd like to get this nagging question solved.