I have similar problem with messages:
- Emergency Stop inoperative
- KSS12041 Ackn.: Position comparison robot controller <-> safety controller not possible.
- KSS15085 Ackn.: Controller in failsafe state.
- KSS01205 Ackn.: Zyk_PosIPO cycle time.
I take KRCDiag and examine of logs and I found some logs:
ERROR iHnf1 22:21:22.969 : Cycle 17843. Wrong cycle timing. Delayed for 32015 us (Min: 6000 us, Max: 18000 us). Source: PLC cycle watchdog
ERROR iHnf1 22:21:22.969 : Cycle 17843: cycle time violated (source: 703).
ERROR iHnf1 22:21:22.969 : InterfaceSetTimingViolationFailureState(): Timing-violation SOS_FAILURE_STATE_IS_ACTIVE
WARN iHnf2 22:21:22.969 : switching timer source to TS_TSC
ERROR iHnf1 22:21:22.969 : Cycle 17843. Wrong cycle timing. Delayed for 32017 us (Min: 6000 us, Max: 18000 us). Source: Generic high precision time
ERROR iHnf2 22:21:22.969 : Cycle 17843. Wrong cycle timing. Delayed for 32097 us (Min: 6000 us, Max: 18000 us). Source: PLC cycle watchdog
ERROR iHnf2 22:21:22.969 : Cycle 17843: cycle time violated (source: 703).
ERROR iHnf2 22:21:22.969 : InterfaceSetTimingViolationFailureState(): Timing-violation SOS_FAILURE_STATE_IS_ACTIVE
ERROR iHnf2 22:21:22.969 : Cycle 17843. Wrong cycle timing. Delayed for 32121 us (Min: 6000 us, Max: 18000 us). Source: Generic high precision time
ERROR iHnf1 22:21:22.970 : hnfDoSafeOSCyclic: Cycle time violated in cycle 17843
ERROR iHnf2 22:21:22.970 : hnfDoSafeOSCyclic: Cycle time violated in cycle 17843
INFO dKRC 22:21:22.977 : Meldung Nr. M_15058 abgesetzt
INFO tMELD 22:21:22.977 : M_15058: "Die Steuerung ist im fehlersicheren ..."
WARN tNextGen 22:21:22.980 : CNextGenPowerBrakeControl: Wrong hardware state in "ReadyToMove". (A4)
WARN tNextGen 22:21:22.980 : CNextGenPowerBrakeControl: Wrong hardware state in "ReadyToMove". (A5)
WARN tNextGen 22:21:22.980 : CNextGenPowerBrakeControl: Wrong hardware state in "ReadyToMove". (A6)
BASIC tNetP052 22:21:22.983 : <SYS-X48>: KCP-Connected State-Change: Old='KCP_Plugged' -> Act='KCP_Unplugged'
WARN tNextGen 22:21:22.984 : CNextGenPowerBrakeControl: Wrong hardware state in "ReadyToMove". (A1)
WARN tNextGen 22:21:22.984 : CNextGenPowerBrakeControl: Wrong hardware state in "ReadyToMove". (A2)
WARN tNextGen 22:21:22.984 : CNextGenPowerBrakeControl: Wrong hardware state in "ReadyToMove". (A3)
WARN tLRS_HP 22:21:22.984 : laghpStateRegular: Spontanantriebsstopp
INFO tLRS_HP 22:21:22.984 : Meldung Nr. M_108 abgesetzt
ERROR tCabCtrlFa 22:21:22.984 : virtual void CCabCtrlOpProcessSafetySignals::DevelopIO(): No communication with Safety! Interface versions: CabCtrl(13), Safety(0).
INFO tMELD 22:21:22.984 : M_108: "Drehzahl-Stopp aktiv"
INFO tZYK_preIP 22:21:22.992 : Meldung Nr. M_310 abgesetzt
INFO tZYK_preIP 22:21:22.992 : Meldung Nr. M_3186 abgesetzt
INFO tMELD 22:21:22.992 : M_310: "Antriebe durch Safety deaktiviert."
INFO tMELD 22:21:22.992 : M_3186: "Antriebe wurden entladen (Grund: SAFETY)"
It seems motherboard problem in PCH chip because HPET timer in PCH chip in my case. It seems similar.
My thesis some threads in VxWin taking too long time and safety system going to fail safe state reason of thread monitoring. All safety communication lost included the SmartPad and you can see Emergency Stop Inoperative and red banner on top. I tried replace PLC and other related components but no success. I will try new motherboard in few days.