ID-range 294000-294249

294000

Drive error No. Trip.

Description

· The KSD reports a common internal error state. Watch the next errors for detailed information.

· Are there no next error messages, export the code table of the specific KSD into a Log-File with the DSERDW-Tool. The code numbers 162 to 164 tells the last errors. No. 161 reports the actual error state of the KSD.

Reaction

Class

6

· Path-maintaining braking.

· All active commands inhibited

Solution

Class

6

Contact KUKA service team.

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Actual value [-]

DSE drive address.

%3:

Actual value [-]

DSE error id.

Error type

11, Error message from position controller.

294001

Encoder cable failure.

Description

· Encoder cable defective.

· Loose connection.

· Supply voltage missing.

· Encoder defective.

Reaction

Class

6

· Dynamic braking.

· Output “$ALARM_STOP” has signal level 0.

· All active commands inhibited.

Solution

Class

6

· Check encoder cable.

· Check connections.

· Check supply voltage.

· Check encoder and exchange if necessary.

Error type

11, Error message from position controller.

294002

Regulator limit exceeded.

Description

· Following error too big. The axis does not follow the command value.

· Is there only the acknowledge message and not status message then the surveillance in the kernel system has triggered.

Reaction

Class

6

· Maximum braking.

· Active commands inhibited.

· Output “$ALARM_STOP” has signal level 0.

Solution

Class

6

· Check machine data $IN_POS_MA (positioning window axis) and $FOL_ERR_MA (factor for the following error).

· Check power converter.

· Check manipulator and motor.

· Check machine data of controller parameters and gear ratios.

· Check machine data $COM_VAL_MI (limitation of command revolution axis) and $TL_COM_VAL (tolerance for limitation of command revolution).

Error type

11, Error message from position controller.

294003

Motor blocked.

Description

The command torque value supplied by the speed controller exceeds the max. command torque value by more than 30%.

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

Rectify cause of torque overload (reduce velocity, acceleration).

Error type

11, Error message from position controller.

294004

Collision detection.

Description

The motor torque is not located in the specified monitoring range.

Reaction

Class

6

· Path-maintaining braking.

· All active commands inhibited.

Solution

Class

6

· Verify load data.

· Increase size of range if required.

Error type

11, Error message from position controller.

294005

Watchdog interpolation cycle.

Description

DSE did not get a new position value from kernel system for this axis.

Reaction

Class

6

· Dynamic braking.

· All active commands inhibited.

· Output “ALARM_STOP” has signal level 0.

Solution

Class

6

· Check plugs of DSE on MFC and MFC on Motherboard (loos connection).

· If this does not work, exchange DSE or MFC.

Error type

11, Error message from position controller.

294006

Over current.

Description

Intermediate circuit current monitoring safeguard triggered by over-current.

Reaction

Class

6

· Maximum braking.

· Active commands inhibited.

Solution

Class

6

· Rectify fault.

· Reset the fault by pressing the hardware acknowledgement button “ACK” on the DSE I module.

Error type

11, Error message from position controller.

294007

Brake fault.

Description

Brake cable monitoring device has signaled short-circuit, overloading or break in connection.

Reaction

Class

6

· Path-maintaining braking.

· Program execution is stopped.

Solution

Class

6

· Rectify fault.

· Reset the fault by pressing the hardware acknowledgement button "ACK" on the DSE I module.

Error type

11, Error message from position controller.

294008

Error sync. Input drive.

Description

Synchronization error in the DSE drive module.

Reaction

Class

6

Path-maintaining braking. All active commands are inhibited.

Solution

Class

6

Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294009

Synchronization error drive.

Description

An synchronization error occurred within the drive module.

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

Rectify synchronization error and do nc reset.

Error type

11, Error message from position controller.

294010

Monitoring of the actual velocity.

Description

Fault in control loop:

· Motor cables of two axes interchanged.

· Error in the axis assignment.

· Power module defective.

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

· Check motor cables.

· Eliminate fault in the control loop / error in the axis assignment.

· Check power module and exchange if necessary.

· In the case of an unmastered resolver, remaster the robot.

Error type

11, Error message from position controller.

294011

Servo bus disturbance.

Description

Defect in

· Bus connection.

· Bus module.

· Bus driver.

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

Change the element.

Error type

11, Error message from position controller.

294012

Motor cable.

Description

The DSE-drive reports heavy load on the motor cable.

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Check motor. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294013

Motor cable.

Description

The DSE-drive reports a short circuit in the motor cable.

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Check motor cable. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294014

Over current.

Description

The DSE-drive reports over current.

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Check motor. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294015

Failure of motor phase.

Description

Power module or intermediate circuit voltage discharged.

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

· Switch on drives.

· Check power module and DSE.

Error type

11, Error message from position controller.

294016

Heat sink temperature.

Description

Thermostatic switch on the heat sinks of the servo output stage signals that the temperature of the output stage transistors is too high.

Reaction

Class

6

· Path-maintaining braking.

· All active commands inhibited.

Solution

Class

6

Rectify cause of the overheating (e.g. reduce the load).

Error type

11, Error message from position controller.

294017

Drive error No. 71.

Description

The DSE-drive reports error No.71.

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294018

Wrong drive parameter PR1.

Description

The DSE-drive reports parameter error No.1.

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294020

Drive error No. 79.

Description

The DSE-drive reports error No. 79 (communication error EEPROM control).

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294021

Drive error No. 80.

Description

The DSE-drive reports error No.80 (communication error EEPROM power).

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294022

Drive error No. 91.

Description

The DSE-drive reports error No.91 (external error).

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294023

Drive error No. 105.

Description

The DSE-drive reports error No.105.

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294024

Drive error No. 106.

Description

The DSE-drive reports error No.106 (check sum error in DSE-drive).

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294025

Axis without power.

Description

Denoted axis is without power.

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

Check hardware.

Error type

11, Error message from position controller.

294026

Drives Error No.[error number], see parameter 4.

Description

The DSE-drive reports an error. The error is described by error parameter No.4.

Reaction

Class

6

Path-maintaining braking. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

%4:

Actual value [-]

Error number.

Error type

11, Error message from position controller.

294027

General drive error, see parameter 4.

Description

The DSE-drive reports a general error. The error is described by error parameter No.4.

Reaction

Class

6

Axis stop. All active commands are inhibited.

Solution

Class

6

Talk to service personal. Rectify fault. Reset the fault on the DSE-module.

%4:

Actual value [-]

Error number.

Error type

11, Error message from position controller.

294028

Single brake module of drive deactivated.

Description

The single break module is activated in the axis servo file, although there ist no module available in the moment.

Reaction

Class

1

Output a warning.

Solution

Class

1

Deactivate single break module in the axis servo file.

Error type

11, Error message from position controller.

294029

Brake channel closed.

Description

Brakes have not been opened because not all axis of this brake channel are active.

Reaction

Class

1

Errors: e.g. Following error or Motor blocking.

Solution

Class

1

Move all axis at one breakchannel together or use seperate brake control.

Error type

11, Error message from position controller.

294030

Slave: wrong amplifier.

Description

The amplify parameter is wrong in the DSE drive controller.

Reaction

Class

6

Path-maintaining braking. All active commands are inhibited.

Solution

Class

6

Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294031

Slave: deviation warning.

Description

The position deviation between master and slave drive exceeds the warning limit.

Reaction

Class

1

Output a warning.

Solution

Class

1

Reduce speed.

Error type

11, Error message from position controller.

294032

Slave: deviation alarm.

Description

Follow-up message to status message: "Deviation alarm master-slave <...>".

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

Acknowledge message.

Error type

11, Error message from position controller.

294033

Slave: critical deviation.

Description

Follow-up message to status message: "Deviation critical master-slave <...>".

Reaction

Class

6

· Maximum braking

· All active commands inhibited.

Solution

Class

6

Acknowledge message.

Error type

11, Error message from position controller.

294034

Slave: speed deviation.

Description

Follow-up message to status message: "Speed deviation master-slave <...>".

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

Acknowledge message.

Error type

11, Error message from position controller.

294035

ASR error.

Description

The system deviation has exceeded a limit value due to excessive slip.

Reaction

Class

6

· Maximum braking.

· All active commands inhibited.

Solution

Class

6

Check the hardware.

Error type

11, Error message from position controller.

294036

KR3 error.

Description

There is an error in the KR3 module.

Reaction

Class

6

Path-maintaining braking. All active commands are inhibited.

Solution

Class

6

Rectify fault. Reset the fault on the DSE-module.

Error type

11, Error message from position controller.

294037

DSE watchdog error.

Description

The maximum permissible calculation time was exceeded.

Reaction

Class

5

Path-maintaining braking. All active commands are inhibited.

Solution

Class

6

Rectify fault. Reset the fault on the DSE-module.

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Drive type [-]

Drive type of the axis.

%3:

Block number [-]

Block number in nc program.

Error type

11, Error message from position controller.

294038

Unknown DSE-drive error ID.

Description

The DSE has sent an unknown drive-error ID.

Reaction

Class

6

Stop of axis.

Solution

Class

6

Remedy error case and do nc reset.

Error type

11, Error message from position controller.

294039

Control enable is blocked, this may also be caused by errors of other axes.

Description

Control enable is blocked, this may be cause by error of other axes.

Reaction

Class

5

Abrupt axis stop, feed hold for the other axes.

Solution

Class

6

Rectify blocked control enabling an do nc reset.

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Drive type [-]

Drive type of the axis.

%3:

Status [-]

State of flag ‘stop_drive’

%4:

Status [-]

Status for flag ‘emergency_stop’.

Error type

11, Error message from position controller.

294040

DSE drive was stopped because of an error in another drive.

Description

The DSE drive was stopped because of an error in another drive.

Reaction

Class

5

Abrupt axis stop, feed hold for the other axes.

Solution

Class

6

Remedy error in other axis and do nc reset.

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Drive type [-]

Drive type of the axis.

%3:

Block number [-]

Block number in nc program.

Error type

11, Error message from position controller.

294041

Control enable is blocked, because drive has no power.

Description

Control enabling is blocked because drive has no power.

Reaction

Class

5

Abrupt axis stop, feed hold for the other axes.

Solution

Class

6

Switch on power for drive.

Error type

11, Error message from position controller.

294042

Control enable is blocked, because hardware re-initialization is running.

Description

Control enabling is blocked at the moment because hardware re-initialization is running.

Reaction

Class

5

Abrupt axis stop, feed hold for the other axes.

Solution

Class

6

Wait until re-initialization is finished.

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Drive type [-]

Drive type of the axis.

%3:

Block number [-]

Block number in nc program.

Error type

11, Error message from position controller.

294043

Fan error. Change module as soon as possible for avoiding breakdown.

Description

Fan on power converter of a Cobra control is defect.

Reaction

Class

1

There is no sufficient cooling of the converter.

Solution

Class

1

· Check for free rotatability of fan.

· Change fan.

Error type

11, Error message from position controller.

294044

Deviation in absolute position value DSE - RDC.

Description

The absolute position value, calculated on DSE, differs from the value on RDC for more than 1/4 resolver turn.

Reaction

Class

5

· Ramp-down braking

· All active commands inhibited.

Solution

Class

6

-

Error type

11, Error message from position controller.

294045

Encoder cable failure external.

Description

· Encoder cable external position input defective.

· Loose connection.

· Supply voltage missing.

· Encoder defective.

Reaction

Class

6

· Dynamic braking.

· All active commands inhibited.

· Output $ALARM_STOP has signal level 0.

Solution

Class

6

· Check encoder cable.

· Check connections.

· Check supply voltage.

· Check encoder and exchange if necessary.

Error type

11, Error message from position controller.

294046

Force controller error.

Description

Force sensor signal does not fit to movement:

· The actual force changes and the position does not change.

· The position changes and the actual force does not change.

This surveillance is only active while the force controller is active!

Reaction

Class

1

· Maximum braking

· Active commands inhibited.

· Output $ALARM_STOP has signal level 0.

Solution

Class

1

· Check force sensor.

· Check force sensor cable.

· Check RDC plug in board (KSK).

· Check gun bearings and guidings.

Error type

11, Error message from position controller.

294047

Master-Slave maximum position exceeded.

Description

Maximum position of the slave of 800000 increments exceeded.

Reaction

Class

1

Calculation errors in actual velocity, following error and deviation.

Solution

Class

1

Change working area of the axis so that the position is always in +- 8000000 increments.

Error type

11, Error message from position controller.

294048

Allowed maximum force exceeded.

Description

The force sensor signal is higher than FORCE_MAX + UPPER_LIMIT_TOL after activation of force control ($Force[axis] > FORCE_LIM).

Reaction

Class

6

· Maximum braking.

· Active commands inhibited.

· Output $ALARM_STOP has signal level 0.

Solution

Class

6

· Check force sensor value $Force_act[axis] in Varkor.

· Check force sensor and cable.

· Trace testgroup 11-Force control to determine if the controller overshoots too much.

Error type

11, Error message from position controller.

294049

I2T-Monitoring: Current limit of the motor cable exceeded 95 per cent.

Description

The current limit of the motor cable exceeds 95 per cent.

Reaction

Class

1

Output of a warning message.

Solution

Class

1

Reduce load.

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Drive type [-]

Drive type of the axis.

%3:

Actual value [0,1%]

Actual current limit of the motor cable.

Error type

11, Error message from position controller.

294050

Current limit of the motor cable exceeded 100 per cent (wait about 60s).

Description

The current limit of the motor cable exceeded 100 per cent.

Reaction

Class

7

· Ramp-down braking.

· All active commands inhibited.

Solution

Class

6

Wait about 60s.

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Drive type [-]

Drive type of the axis.

%3:

Actual value [0,1%]

Actual current limit of the motor cable.

Error type

11, Error message from position controller.

294051

I2T-Monitoring: Current of motor cable falls below 100 per cent again.

Description

The current of motor cable falls below 100 per cent again.

Reaction

Class

1

Output of a warning message.

Solution

Class

1

-

Parameter

%1:

Logical axis number [-]

Logical axis number P-AXIS-00016 of affected axis.

%2:

Drive type [-]

Drive type of the axis.

%3:

Actual value [0,1%]

Actual current limit of the motor cable.

Error type

11, Error message from position controller.

294053

Maximum acceleration exceeded.

Description

The safety controller has detected an axis acceleration that has been greater than the configured safety parameter.

Reaction

Class

1

The robot stops.

Solution

Class

1

The message has to be acknowledged then the robot can move on.

Error type

11, Error message from position controller.

294054

Maximum speed exceeded.

Description

The safety controller has detected an axis speed that has been greater than the configured safety parameter.

Reaction

Class

1

The robot stops.

Solution

Class

1

The message has to be acknowledged then the robot can move on.

Error type

11, Error message from position controller.

294055

Brake test failed.

Description

The brake test checks the torque of the mechanical brakes. The torque of the brake of the mentioned axis is under the necessary torque limit.

Reaction

Class

1

The robot cannot be used until the torque is o.k. again.

Solution

Class

1

The brake or motor must be replaced.

Error type

11, Error message from position controller.

294056

Gun moves force controlled under FORCE_LIM.

Description

· The gun opens wider than the corresponding position to FORCE_LIM and is stopped to avoid an uncontrolled opening of the gun.

· This surveillance is only active while the force controller is active!

Reaction

Class

6

· Maximum braking.

· Active command inhibited.

· Output $ALARM_STOP has signal level 0.

Solution

Class

6

· Check force sensor.

· Check force sensor cable.

· Check RDC plug in board (KSK).

· Trace testgroup 11-Force control to determine if the controller oszillates.

Error type

11, Error message from position controller.

294057

Increase in force values in force control is missing.

Description

The force sensor value does not increase when driving to a force controlled point:

· Force sensor, KSK, cables, RDC,... broken or not right connected.

· Gun tips don't touch the part.

Reaction

Class

6

· Maximum braking.

· Active commands inhibited.

· Output $ALARM_STOP has signal level 0.

· The force controller is not activated. The motor is stopped to avoid moving to P_WELD in the part and damage the gun.

Solution

Class

6

· Check force sensor.

· Check force sensor cable.

· Check RDC plug in board (KSK).

Error type

11, Error message from position controller.

294058

Measuring range of force sensor exceeded.

Description

· The measuring range of force sensor is -1500 to +6500 increments. Are these values exceeded we do not have a correct signal anymore.

· The reason can be a reset of the sensor under pressure or long time drift in the force signal.

Reaction

Class

1

The value of the force sensor is wrong.

Solution

Class

1

· Check if the force value in increments is in between +- 50 INC with an open gun.

· Check if the reset works properly and is not set under pressure.

Error type

11, Error message from position controller.

294059

Deviation of Resolver shut down position from actual position.

Description

Resolver shut down position is not identical with the actual position.

Reaction

Class

1

Mastering of this axis will be discarded.

Solution

Class

1

· Check brakes.

· Set mastering.

Error type

11, Error message from position controller.

294060

The motor temperature indicated greater than 155 degrees centrigrade.

Description

The motor temperature of the axis indicated is greater than 155 °C. (Signaled by PTC element in the motor winding.)

Reaction

Class

5

· Path-maintaining braking.

· All active commands inhibited.

Solution

Class

6

· Reduce mechanical load.

· Rectify any faults.

Error type

11, Error message from position controller.

294061

Target speed monitoring exceeded.

Description

Reaction

Class

5

Solution

Class

6

Error type

11, Error message from position controller.