KUKA robots can show a range of errors, which generally fall into categories related to hardware, software, communication, or programming. Below are some common KUKA robot error types, along with tips for troubleshooting them:
### 1. **Motion Errors**
- **KSS15001 – Mastering Required**: This error means that one or more robot axes need mastering. Master the affected axes with a mastering tool or method, as instructed in the KUKA documentation.
- **KSS15004 – Overload on Axis**: An overload error indicates excessive load or force on a specific axis, usually due to incorrect payload settings. Verify the payload configuration and adjust it if necessary.
- **KSS15321 – Safe Stop**: This error can occur when the robot detects an unsafe condition, like exceeding speed or torque limits. Ensure all safety conditions are met and reset the system.
### 2. **Positioning and Calibration Errors**
- **KSS13005 – Position Deviation**: This occurs if the robot can't reach the programmed position due to external interference or a calibration issue. Recalibrate the robot or re-master the affected axes.
- **KSS15002 – Collision Detection**: If the robot detects an obstruction or collision, this error will appear. Inspect the robot path and the surroundings, and remove any obstacles. You may also need to adjust collision sensitivity.
### 3. **Communication Errors**
- **KSS00202 – Network Connection Error**: If there is a loss in communication between the robot controller and external systems (like a PLC), check network cables and connections.
- **KSS26006 – Fieldbus Error**: This error occurs when there’s an issue with fieldbus communication, often due to configuration or wiring issues. Verify that fieldbus settings match and that connections are secure.
### 4. **Safety Errors**
- **KSS01530 – Safety Stop Error**: This indicates that an emergency stop or a safety limit has been reached. Check the emergency stop buttons, safety doors, and sensors for activation.
- **KSS01506 – Emergency Stop**: This error is triggered if any of the emergency stops are pressed. Check and reset all emergency stop buttons on the controller, teach pendant, and any external connected devices.
### 5. **Software and Programming Errors**
- **KSS14001 – Program Path Not Found**: This error means the controller can't locate the program file. Verify the program path and load the correct file.
- **KSS00404 – Subnet Mask Error**: Incorrect network settings, such as subnet mask mismatch, can cause this error. Confirm and adjust network configurations if needed.
- **KSS01056 – Variable Not Defined**: This error arises if a variable in the program is undefined. Review the program code and ensure all variables are declared and initialized.
### 6. **Battery and Power Supply Errors**
- **KSS15005 – Battery Error**: If the robot backup battery is low or dead, this error will appear. Replace the battery and reset the robot.
- **KSS00200 – Power Supply Error**: This error can appear when the robot experiences inconsistent power. Inspect the power source, cables, and connectors for any faults.
### 7. **Encoder and Sensor Errors**
- **KSS15112 – Encoder Error**: This error indicates an issue with the encoder feedback on a specific axis. Reboot the robot to see if it clears; if not, check encoder connections or replace the encoder if needed.
- **KSS15014 – Brake Error**: If there’s a problem with the brake on any axis, this error will show up. Check the brake and related wiring; in some cases, the brake may need to be replaced.
### Troubleshooting Tips
- **Check Documentation**: The KUKA error codes in the robot's manual provide specific troubleshooting steps.
- **Log Analysis**: The KUKA SmartPad or KUKA WorkVisual tool can help you analyze logs for detailed error diagnostics.
- **Resetting the Robot**: Sometimes, errors can be cleared by rebooting the controller or performing a warm start.
- **Support**: For persistent issues, contacting KUKA support may be necessary.
