Posts by Janusz robotyk

    Hi Kheirou,

    each PR is saving values for all axes of all groups declared in MAINTENANCE menu during Controlled Start.

    In your case, by adding another axes to Group 2, there is unitialized position data for axis 2 and 3, and
    that is causing the all the data of PR (including Group 1) to become uninitialized.

    You may try to export POSREG.VR before adding additional axes, and then load this file after you add additional axes - it may restore saved data for axes in Group 1 and axis in Group 2, but I'm not 100% sure it would work.


    I created image from HDD disk using Macrium software, I think copying files wouldn't be sufficient.

    About soldering - I couldn't find pin assigment and description because documentation for this particular disk is no longer available.

    But, when no pins were jumpered BIOS did discover the disk, the BSOD (Blue Screen of Death) appeared every time before Windows loading.

    Only when pins were jumpered just like below (Master and Slave connection), BSOD did not appeared.

    My other concern is, when I connect either HDD or SSD drive to my laptop and try to start Windows from external drive, the Windows is loading just like I described in my previous post (resume bar is filled, and then screen turns black). I don't know, if it's an issue with starting the Windows XP Embedded on laptop with originally installed Windows 10, or is it an issue with disk.

    Anyway, I asked disk manufacturer to provide me with pinout documentation for SSD drive to check, if connection is OK.

    Hello guys,

    Recently I have tried to copy the content of original Kuka HDD disk to new PATA disk.

    Controller is KR C2 edition 05, and soft version i V5.4.7 build 66.

    I managed to make an image backup of HDD drive using Macrium Reflect software.

    I soldered appropiate pins on PATA disk to set disk as Master (there were too little space between disk and adapter to attach a jumper), and attached the PATA -> SATA converter.

    Then, I formatted PATA disk, and restored disk image onto PATA drive also with help of Macrium Reflect software.

    After I plug in PATA disk and turn on the controller, disk is recognized in BIOS - disk name "SQF-P25M4-16G-P9C" is visible on hardware list.

    So far, so good.

    After that, "Windows Resume Loader" window appears, and when I choose "Continue with system resume", the next screen "Resuming Windows..." appears.

    When the loading bar is full, the screen becomes all-black, and Windows is not starting up.

    At this time, the red diode on adapter stops blinking, which I assume means that drive in no longer processing data.

    In other threads I saw some users suggested using other software for disk cloning (for example Acronis, or Norton11) - I haven't tried them yet, because last time I couldn't stop the controller and cause more downtime.

    Maybe you guys had similar issue in the past and could provide me with some ideas for me to try? I would greatly appreciate your help.


    Hey Vlad,

    you can either

    - decrease the acceleration of the movement (for example : L P[1] 100mm/sec CNT 100 ACC25)

    - decrease the speed of motion segments

    - add PTH instruction and try to reduce the CNT parameter of the motion instruction

    You can execute Controlled Start and set "NO" in 2. Karel Prog in select menu.

    You can still call those programs within your programs, but they will not show in select menu.

    In newer versions on controller's software, you cannot delete system macros (GETDATA.MR, SENDDATA.MR etc) for some reason.


    I have a problem with DI/DO module - it seems like there is no output voltage to Digital Outputs.

    I measure input voltage of module, and it's 24V.

    I noticed, that there is a diode DS2 which is blinking red with 60Hz frequency with following pattern - for every 15 red blinks of diode DS2, this diode flashes with green colour once.

    I think, that may be indication of some error, but I cannot find any troubleshooting manual for this module.

    I shared more pictures and movie at google drive:…TdImZfix6nhHM?usp=sharing

    This seem strange, because controller and this module worked fine at my company site, but after transport to customer site this module stopped working. I checked the connectors, and there seem to be no external damage.

    If you have any idea, what could be causing this problem, I'd appreciate any help.

    More information about robot:

    - KUKA 180-2 PA

    - controller (V)KRC2 ed05, KSS V5.4.7

    Hey M_Benton,


    Current and peak values of torque occuring during one cycle are saved/remembered until next servo power ON, then they are reset, zero-ed and measured again.

    You can generate and check the report of servo-off events (MENU -> STATUS -> SERVO-OFF HISTORY -> F4 [REPORT]), where you can find history of Collision Detection:

    As you can see, in my case, when disturbance torque value on axis 6 is around 100% of value set by COL_GUARD_ADJUST (which in your case is +/-16.1 A), robot immidiately stops by SRVO-050 Collision Detect Alarm.

    Hey M_Benton,

    I think values in parentheses are min./max. allowable values of disturbance torque (measured in Amps) - you can manually set those values by adjusting Collision Guard (the lower the value, the higher disturbance torque is allowed before Collision alarm occurs).

    Values of 22.5 and -23.8 are peak dirsturbance torques received during the cycle. In your case, those both values are bigger then maximum allowable torque, so I'd say that some external force was applied to robot during this run.


    Recently I managed able to revive some long-time retired Kuka robot.

    Fortunately for me, I have my hands on some spare parts for KRC2 controller.

    I would like to share my experience with solving those issues, maybe someone will find it helpful.

    Patient data :

    - KUKA 200 comp

    - controller (V)KRC2 ed05, KSS V5.4.14

    Error messages :

    - KCP: connection error WATCHDOG_ERROR

    - Local Protective Stop (QE)


    - External EMERGENCY STOP Pressed

    - Safety circuit for drives not ready

    - Drives contractor off

    - Accu voltage at PM1 below 22 volts during last buffering

    Visible symptoms :

    - KCP buttons not responding (including mode selector and E-Stop). When connected external mouse and keybord it's possible to operate KCP.

    - 2 red LEDs on KPS 600 are shining with still red light

    What I did:

    - replace all possible fuses - no result

    - jumper X11 plug for standalone operation - no result

    - replace KCP - no result

    - replace MFC3 card - bingo!

    After replacing MFC3 card, red LEDs on KPS 600 are blinking rapidly, all buttons on KCP are responding, and there's no error messages left.

    KPS 600 after replacing MFC3.mp4