库卡机器人kuka 故障信息与故障处理

Systemmeldungen05.03.01en1of322SOFTWAREKRC...SystemMessagesKUKASystemSoftware(KSS)Issued:18May2006Version:012of322Systemmeldungen05.03.01eneCopyrightKUKARoboterGmbHThisdocumentationorexcerptstherefrommaynotbereproducedordisclosedtothirdpartieswithouttheexpresspermissionofthepublishers.Otherfunctionsnotdescribedinthisdocumentationmaybeoperableinthecontroller.Theuserhasnoclaimstothesefunctions,however,inthecaseofareplacementorservicework.Wehavecheckedthecontentofthisdocumentationforconformitywiththehardwareandsoftwaredescribed.Nevertheless,discrepanciescannotbeprecluded,forwhichreasonwearenotabletoguaranteetotalconformity.Theinformationinthisdocumentationischeckedonaregularbasis,however,andnecessarycorrectionswillbeincorporatedinsubsequenteditions.Subjecttotechnicalalterationswithoutaneffectonthefunction.3of322Systemmeldungen05.03.01enContents1Systemmessages4................................................SystemMessages4of322Systemmeldungen05.03.01en31SystemmessagesThistablecontainsanoverviewofthesystemmessagesthatcanbedisplayedinthemes-sagewindowofthegraphicaluserinterface.Asystemmessageconsistsofthefollowingitemsofinformation:12:18:021342WorkenvelopeexceededKCPC...TimeNo.SourceMessage12:18:031376KCPActivecommandsinhibitedMessagegroupMessagetimeMessagenumberOriginatorofthemessageMessagetextMessagegroupThemessagegroupisthecategorytowhichasystemmessagebelongs.Itisrepresentedbyasmallicon.NotificationmessageNotificationmessagescontaininformationorindicateoperatoractions,programmingerrorsandoperatorerrors.Notificationmessagesarepurelyforinformationpurposesanddonotinterruptprogramexecution.StatusmessageStatusmessagesindicatethestatusofthesystem.Statusmessagesarealsoinformationalincharacter,butcaninterrupttheapplicationprogramtoacertainextent.Astatusmessageisautomaticallydeletedassoonasthestatusthattriggeredthemessageisnolongerapplicable.AcknowledgmentmessageThesefrequentlyappearfollowingastatusmessage(e.g.“EMERGENCYSTOP”)andmustbeconfirmedbymeansofasoftkey.Anacknowledgmentmessagemayinterruptanapplicationprogramordisablejogmode.Itindicatesdisruptiontoprogramexecution.DialogmessageTheoperatormustrespondtothesemessagesusingasoftkey.Adialogmessagestopsarunningprogram.Itisautomaticallydeletedwhenoneofthesoftkeysofferedispressed.Theprogramisthenresumed.1Systemmessages(continued)5of322Systemmeldungen05.03.01enMessagetimeThemessagetimeindicatesthesystemtimeatwhichthemessagewasgenerated.MessagenumberWiththeaidofthemessagenumber,thecorrespondingcause,effectandanyavailableremedycanquicklybelocatedinthelistofsystemmessages.OriginatorofthemessageThemoduleresponsibleforthesystemmessageisindicatedinthiscolumn.MessagetextTheactivesystemmessageisdescribedhereingreaterdetail.Pleasenote:Eachsystemmessageismosteasilyfoundusingthemessagenumber.Forthispurpose,allthemessageshavebeenarrangedhereinatabularstructure.1EMERGENCYSTOPMessagenumberMessagetextTypeofmessageCauseDescribesthereasonforthecurrentsystemmessage.Describestheresponseofthecontrollerwhenthesystemmessageinquestionisgenerated.Describestheremedialmeasure(s)thatcanbetakentoeliminatetheproblem.EffectRemedyLinesareonlyincludedinthetablewherenecessary.Whenamessageisgenerated,placeholderssuchas“<%1>”arereplacedwithrelevantvalues.SystemMessages6of322Systemmeldungen05.03.01en1EMERGENCYSTOPCauseEMERGENCYSTOPbuttonpressed.EMERGENCYSTOPcircuitbroken.EMERGENCYSTOPtriggeredbyprogram.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyReleasetheEMERGENCYSTOPpushbutton.CheckEMERGENCYSTOPpushbuttonandEMERGENCYSTOPcir-cuit.Rectifyandacknowledgethesignalledfault.2InternalerrorCauseInternaltestofKRCsoftware.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyAcknowledgemessage.3MessagebufferoverflowCauseThemessagebuffercontainingthemessagesthatarecurrentlyactive(acknowledgementandstatusmessages)hasreachedacertaincapacitylimit.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyRectifyandacknowledgethesignalledfaults.4Bufferbatteryvoltagelow<powermodulenumber>CauseThevoltageofthebackupbatteryistoolow.EffectNexttimethecontrollerisswitchedoff,itwillnolongerbepossibletowritecompletelytotheharddisktherobotdatathatneedtobesaved.RemedyExchangethebattery.1Systemmessages(continued)7of322Systemmeldungen05.03.01en5Malfunction<KCPorRCP>CauseKCPdefective.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyExchangeKCP.6Transmissionerror<KCPorRCP>CauseConnectiontoKCPisfaulty.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyCheckKCPcable.7I/ODrivernotready:<drivernumber><0>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.8SystemtimeinvalidCauseThesystemtimeisinvalid,accordingto“TIME_HW_FAILURE”,andhasbeensettotheinitialvalue.EffectSystemtimehasbeeninitializedwiththesetting01.01.9300:00:00,00.RemedyUpdatethesystemtimeusingthe“syszeit”form.9MFC--OvertemperatureCauseMFCovertemperature.EffectPath--maintainingbraking.RemedyCheckfanincontrolcabinet.ExchangeMFCifnecessary.SystemMessages8of322Systemmeldungen05.03.01en10Errordigitaloutputs...CauseShortcircuitatoutputs1to8orshortcircuitatoutputs9to16.EffectMaximumbraking.RemedyRectifyfault.11TaskstackforcommandexecutiontoosmallCauseOccursduringprogramorcommandexecution.KRLprogramorcommandhastoolittletaskstackavailableforexecu-tion.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyAltertheprogramstructureandresettheprogram.12ToomanymessagesCauseToomanymessageshavebeengeneratedcyclically.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyAwarmstartoftheACR.13ErrorsafetyloopCauseAchannelhasfailedormorethanoneenablingswitchhasbeenpressed.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyEliminatefaultanddonotpressmorethanoneenablingswitch.1Systemmessages(continued)9of322Systemmeldungen05.03.01en14SoftPLC:<Parameter>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.15Monitoring600VPowersupply<KPSnumber>CauseKPSintermediatecircuitvoltageoverload.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyReduceload.16ErrorwhilereadingO--FileCause--Errorduringloading/readingof“ident_vx.o”:memoryorfilenotfound.Monitoringiscarriedoutinthewritefunction“w_ident_state”.EffectJumptotheendinloaddataprogram.RemedyCopythefile“ident_vx.o”tothedirectory“/ir_spec/l_ident”,orincreasememorybychangingthevalue“VxWinRAM”intheregistry.17Wrong/unknownhardwarefoundCauseDuringsetup,thewrongcontrollertype(KRC1,KRC1A,KRC2)wasselectedorthehardwareconfigurationisinvalid.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyCarryoutsetupagainoralterhardwareconfiguration.18ServobusDSE--No.<DSEnumber>participantNo.<IBSparticipantnumber>unknownCauseAnunknowndevicewhichcannotbesupportedhasbeeninsertedinIn-terbus.EffectMaximumbraking.Allactivecommandsinhibited.RemedyRemoveunknowndevicefromservobus.SystemMessages10of322Systemmeldungen05.03.01en19Failureofmotorphase<axisnumber>CausePowermoduleorintermediatecircuitvoltagedischarged.EffectMaximumbraking.Allactivecommandsinhibited.RemedySwitchondrives.CheckpowermoduleandDSE.20ExternalEMERGENCYSTOPPressedCauseEMERGENCYSTOPbuttonpressed.EmergencyStoptriggeredbysoftware.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyRectifyandacknowledgethesignalledfault.ChecktheEMERGENCYSTOPpushbutton.21SecondmotorcablenotconnectedCauseThesecondmotorcableisnotconnectedorisconnectedincorrectly.Theadditionalcablecontainstwowireswhichareconnectedtotherobot.ThereturnsignalisconnectedtotheKPSX114,pin7.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyChecksecondmotorcableandreturnsignalatKPSX114,pin7.22MainboardovertemperatureCauseControlcabinetfanfailure.Ambienttemperaturetoohigh.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyCheckfan.Exchangefanfilter.Reduceambienttemperature.1Systemmessages(continued)11of322Systemmeldungen05.03.01en23KCPprototypeCauseTheconnectedKCPisaprototypedevice.EffectThereisnoKCPwatchdogfunction.RemedyExchangeexistingKCPforaseriesproductionmodel.24Slipexceeded<axisnumber>CauseThesystemdeviationhasexceededalimitvalueduetoexcessiveslip.EffectMaximumbraking.Allactivecommandsinhibited.RemedyCheckhardware,etc.25Brakecooldowntime<axisnumber>;<coolingtime>secondsCauseThebrakeoftheaxisspecifiedhasgottoohot.EffectThedrivesarelockedforthedurationofthecoolingtime.RemedyWaitforthedurationofthebrakecoolingtime.26Module<axisnumber>KSD--<maximumcurrentoftheKSD>re-quiredCauseThemaximumcurrentofthedevicedoesnotmatchtheconfiguredmaxi-mumcurrent.27ToomanyparticipantswithindrivebusDSE<DSEnumber>CauseToomanydevicesinInterbusringcauseanexcessivelylongIBSwordlength.EffectMaximumbraking.Allactivecommandsinhibited.RemedyReducenumberofdevicesorwordlength.SystemMessages12of322Systemmeldungen05.03.01en28DrivebusDSE<DSEnumber>participantno.<IBSparticipantnum-ber>doesnotexistCauseInterbusconfigurationandphysicalstructuredonotmatch.EffectMaximumbraking.Allactivecommandsinhibited.RemedyCoordinateInterbusconfigurationandhardware.29DrivebusDSE<DSEnumber>participantno.<IBSparticipantnum-ber>notconfiguredCauseInterbusconfigurationandphysicalstructuredonotmatch.EffectMaximumbraking.Allactivecommandsinhibited.RemedyCoordinateInterbusconfigurationandhardware.30ConfigurationofdrivebusDSE1toolongCauseTheconfigurationgivesrisetoexcessiveIBSwordlengthduetotoomanyInterbusdevices.EffectMaximumbraking.Allactivecommandsinhibited.RemedyChangetheIBSconfiguration.31Temperaturewarning<drivenumber>CauseThemaximumtemperaturehasbeenexceededinthedrivespecified.EffectMaximumbraking.Allactivecommandsinhibited.RemedyDeterminecauseandeliminateerror.32POSTError:MotorEnableonduringpowerup<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.1Systemmessages(continued)13of322Systemmeldungen05.03.01en33POSTError:Parametertablechecksumfault<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.34POSTError:EncoderFPGAloopbackfault<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.35POSTError:PowerboardFPGAfault<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.36POSTError:A/DFault<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.37POSTError:A/Doffsetfault<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.38POSTError:Invalidparameterfault<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.SystemMessages14of322Systemmeldungen05.03.01en39POSTError:Fatalsystemerror<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.40Error:A/Dtimeoutfault<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.41Commandtimeout<drivenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.42InvalidparameterA<axisnumber>CauseThespecifiedparameterisinvalid.EffectMaximumbraking.Allactivecommandsinhibited.RemedyCorrecttheparametersaccordingly.43Commutationmasteringerror:Servoison<axisnumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.44Firmwareversionmismatch<drivenumber>EffectMaximumbraking.Allactivecommandsinhibited.RemedyCheckconfiguration.1Systemmessages(continued)15of322Systemmeldungen05.03.01en45Commutationmasteringerror:motornotpowered<axisnumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.46Warning:axistoofarfrommasteringposition<axisnumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.47Invalidmotorrating<drivenumber>CauseTheloadonthemotoristoohigh.EffectMaximumbraking.Allactivecommandsinhibited.RemedyTakeappropriatemeasurestoreducetheloadonthemotor(reducedpayload,reducedacceleration,etc.).48Commutationfault<axisnumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.49Invalidcommand<drivenumber>CauseAninvalidcommandhasbeencalled.EffectMaximumbraking.RemedyCorrectcommand.SystemMessages16of322Systemmeldungen05.03.01en50IBS<...>Master:Buserror.ErrordetectioninprocessRemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.51IBS<...>Slave:BuserrorinslavecircleRemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.52POSTError:FPGAFault<powermodulenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.53Outputstatemismatch<powermodulenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.54Wrongmodelnumber<powermodulenumber>RemedyNoonlinehelpiscurrentlyavailableforthissubject.Informationcanbefoundintheoperatinghandbooks.1Systemmessages(continued)17of322Systemmeldungen05.03.01en55InitializationoftheDSErunningCauseDSEisre--initializedwithparameters.Ifthismessageremainsactive,theinitializationwasnotcompletedsuc-cessfully.ThemessagedoesnotappearwiththesettingOffice=TRUEin“hw_inf.ini”.EffectMaximumbraking.Allactivecommandsinhibited.RemedyCheckforerrorsinthemachinedata,particularlyerrorsintheaxisandpowermoduleassignment.Ifthemachinedatahavebeenmodified,comparethemwiththemachinedataontheCDandcorrectthemifnecessary.100RDW<RDCnumber>bootupfailureCauseTheresolver/digitalconverter(RDW)couldnotbeinitializedwhenthecontrollerwasbooted.FaultinRDW,DSEorconnectingcable.EffectDoesnotrunup.RemedyCheckconnectingcableandplug--inconnectionsbetweenRDWandDSE.ExchangeRDW,DSEorcablebetweenRDWandDSE.101DSE<DSEnumber>programbootupfailureCauseThekernelsystemhasnotreceivedthecheckbacksignal“DSEREADY”followingthestartoftheDSEprogram.EffectAllactivecommandsinhibited.RemedyCheckthattheDSEiscorrectlyconnected.ExchangeDSE.SystemMessages18of322Systemmeldungen05.03.01en102Encodercablefailure<axisnumber>CauseEncodercabledefective.Looseconnection.Supplyvoltagemissing.Encoderdefective.EffectDynamicbraking.Output“$ALARM_STOP”hassignallevel0.Allactivecommandsinhibited.RemedyCheckencodercable.Checkconnections.Checksupplyvoltage.Checkencoderandexchangeifnecessary.103Watchdoginterpolationcycle<axisnumber>CauseDSEhasreceivednofeedfromthekernelsystemforthisaxis.EffectDynamicbraking.Allactivecommandsinhibited.Output“$ALARM_STOP”hassignallevel0.RemedyCheckthecontactsintheconnectionsbetweentheDSEandtheMFCandbetweentheMFCandthemotherboard.Ifthisdoesnotimprovethesituation,exchangetheDSEorMFC.104SynchronizationerrorwithDSE<axisnumber>CauseMessagefromthekernelsystem:thekernelsystemhasnotsetthewatchdogtimerformonitoringcommunicationwiththeDSE,ortheDSEhasnotresetthewatchdogtimer.EffectDynamicbraking.Allactivecommandsinhibited.Output“$ALARM_STOP”hassignallevel0.RemedyChecktheconnectionsbetweentheDSEandtheMFCandbetweentheMFCandthemotherboard(looseconnection).Ifthisdoesnotimprovethesituation,exchangetheDSEorMFC.InvestigatewhethertheservobusortheISAbusonthemotherboardisaffectedbyinterference(EMC).1Systemmessages(continued)19of322Systemmeldungen05.03.01en105Transmissionerror<DSEnumber>DSE--RDWCauseDamagedcableorconnectorbetweenDSEandRDC.Cablenotconnectedorconnectedincorrectly.ErrorindatatransmissionbetweenDSEandRDC.EffectDynamicbraking.Allactivecommandsinhibited.Output“$ALARM_STOP”hassignallevel0.RemedyCheckDSEandRDCpowersupply(LEDs).Checkcable(includingshield)andconnections.CheckDSE--RDWserialinterface.Checkthegroundconnectionoftherobotandcabinet.106Performmastering<axisnumber>CausePositionactualvaluedifferenceafterrestarttoogreatandsensormaster-ingnotpossiblebecausesensorlocationrunhasnotbeenperformed.Faultycorrectiondatahavebeenloaded.EffectAllactivecommandsinhibited.RemedyCarryoutmastering.107EMERGENCYSTOPduetodialadjustmentCauseSoftkeyfordialmasteringpressed.Valueassignment$TURN=1.Adjustmentofanabsoluteorincrementalencoderinthe$TURNinstruc-tion.EffectDynamicbraking.Output“$ALARM_STOP”0signal.Allactivecommandsinhibited.RemedyLeavethemasteringmenubypressingtheRecallkeytwice.SystemMessages20of322Systemmeldungen05.03.01en108DynamicbrakingactiveCauseIf“LAGNP”detectsarequestfordynamicbraking(bit“GEN_STOP”setduringmessageprocessing),“LAGNP”generatesthisstatusmessage.EffectDynamicbrakingiscontinueduntiltherobothascometoastandstill,therebyeliminatingthepossibilityofdifferentstatusesin“LAGNP”and“LAGHP”.RemedyOncetherobothascometoastandstill,thismessageisresetwithoutafollow--upmessagebeinggenerated.109Clearfastmeasuringinput<number>Cause“FastMeasurement”hasbeenswitchedon.EffectThemeasuringtoolmustbemovedfreeinordertobeabletoactivate“FastMeasurement”.RemedyMovemeasuringtoolfree.110AdvancedpathprofilenotpossiblewithlinkedexternalaxesCauseCouplingofexternalaxesinhighermotionprofile.RemedyAlterconfigurationaccordingly.111TEPROinactiveCauseSBCnolongersendingasignaltoKRC.(TEPRO=technologicalprocess)EffectSBCinterfaceinoperable.RemedyRe--initializeSBCprogram.112Invalid$TOOL:WorkingenvelopesurveillancenotpossibleCause“$TOOL”isinvalidwhenworkingenvelopemonitoringisactive.EffectNone.RemedyAssign“$TOOL”orswitchoffworkingenvelopemonitoring.1Systemmessages(continued)21of322Systemmeldungen05.03.01en113Rangeoverflow<motiondirection><axisnumber>CauseOverflowoftheactualvalueofanendlessaxis.Actualvalue>+/--90*10E15incrementsor--99999000<$REVO_NUM<999999000.EffectThemotionhasalreadybeenstopped:--eithernormallyduringaxis--specificjogging--orbymeansofmaximumbraking.RemedyTurnaxisbackorremaster.114Workenvelopeno.<workenvelopenumber>violatedCauseTCPisinsideaworkingenvelopewithMODE“INSIDESTOP”oroutsideaworkingenvelopewithMODE“OUTSIDESTOP”.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyDeactivateworkenvelope.Selectthemenuitem“SkipWorkEnvSurveillance”andmovefreeinT1mode.115Drivefreeworkenvelope<workenvelopenumber>CauseTCPisinsideaworkingenvelopewithMODE“INSIDESTOP”oroutsideaworkingenvelopewithMODE“OUTSIDESTOP”andworkenvelopemonitoringisbypassed.RemedyMoverobotoutoftheeffectedworkenvelope.116DSEwatchdogcommand<PVno.>CauseTheDSEhasfailedtoexecuteacommand.EffectRamp--downbraking.Allactivecommandsinhibited.RemedyCheckDSEandMFChardware.SystemMessages22of322Systemmeldungen05.03.01en117Collisiondetectionaxis<axisnumber>CauseThemotortorqueisnotlocatedinthespecifiedmonitoringrange.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyVerifyloaddata,increasesizeofrangeifrequired.118Heatsinktemperature<axisnumber>CauseThermostaticswitchontheheatsinksoftheservooutputstagesignalsthatthetemperatureoftheoutputstagetransistorsistoohigh.EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyRectifycauseoftheoverheating(e.g.reducetheload).119Motortemperature<axisnumber>CauseThemotortemperatureoftheaxisindicatedisgreaterthan155°C.(Sig-naledbyPTCelementinthemotorwinding.)EffectPath--maintainingbraking.Allactivecommandsinhibited.RemedyReducemechanicalload.Rectifyanyfaultsthatmaybepresent.120Motorblocked<axisnumber>CauseThecommandtorquevaluesuppliedbythespeedcontrollerexceedsthemax.commandtorquevaluebymorethan30%.Themotorisshutdownbythe“i*t”monitoringfunctiononreachingan“i*t”valueofapprox.0.75[(Commandtorquevalue/Max