What causes KUKA Robot alarm KRC0019?

Damaged or broken motor power cable with one or more phase conductors severed internally due to excessive bending, cable track wear, or mechanical pinching. Loose or corroded connection at motor power connector X30 on the servo drive side or motor connection box causing intermittent or high-resistance contact. Motor winding failure including open winding, turn-to-turn short, or phase-to-ground fault due to insulation breakdown or thermal damage from previous overload. Incorrect motor cable routing through dress pack or cable track causing excessive stress, minimum bend radius violation, or interference with moving mechanical parts. Servo drive power stage component failure (IGBT module) in one phase preventing proper current flow even with intact motor and cable connections.

How do I fix KUKA Robot alarm KRC0019?

1. Step 1: Immediately check which axis triggered the alarm using smartPAD Diagnosis > Messages. Record the affected axis number and timestamp for documentation and warranty purposes. 2. Step 2: Power down the robot and visually inspect the motor power cable along its entire length for visible damage, cuts, burns, or areas of cable sheath wear exposing conductors. 3. Step 3: At the drive cabinet, disconnect the motor power cable connector X30 from the affected servo drive. Inspect pins for damage, corrosion, or burn marks. Clean contacts with electrical contact cleaner if oxidation is present. 4. Step 4: Using a digital multimeter set to resistance mode, measure continuity between all three motor phase conductors (U-V, V-W, W-U) at the drive-side connector. All readings should be below 2 ohms and balanced within 0.3 ohms of each other. 5. Step 5: Measure insulation resistance from each motor phase to ground (cable shield) using a 500VDC megohmmeter. Readings should exceed 10 megohms. Values below 1 megohm indicate winding or cable insulation failure requiring replacement. 6. Step 6: If cable and motor test good, the servo drive power stage has failed. Replace the affected servo drive module and perform drive commissioning procedure in WorkVisual including EMD measurement and mastering data verification before returning to operation.

KUKA Robot codes

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KUKA Robot Controller

Servo/Axis · Intermediate

Alarm KRC0019

KUKA Robot KRC0019 - Motor Phase Failure

The servo drive has detected an abnormal condition in one or more motor phase connections indicating asymmetry, open circuit, or short circuit in the motor cable or motor windings. This fault is identified during current measurement when the drive expects balanced three-phase current flow but detects significant imbalance or missing phase. Motion is immediately stopped to prevent motor and drive damage.

KUKA RobotServo/AxisIntermediate

KRC0019

KUKA Robot KRC0019 - Motor Phase Failure

Motor Phase Failure

Common Causes

Damaged or broken motor power cable with one or more phase conductors severed internally due to excessive bending, cable track wear, or mechanical pinching
Loose or corroded connection at motor power connector X30 on the servo drive side or motor connection box causing intermittent or high-resistance contact
Motor winding failure including open winding, turn-to-turn short, or phase-to-ground fault due to insulation breakdown or thermal damage from previous overload
Incorrect motor cable routing through dress pack or cable track causing excessive stress, minimum bend radius violation, or interference with moving mechanical parts
Servo drive power stage component failure (IGBT module) in one phase preventing proper current flow even with intact motor and cable connections

Troubleshooting Steps

1Step 1: Immediately check which axis triggered the alarm using smartPAD Diagnosis > Messages. Record the affected axis number and timestamp for documentation and warranty purposes.
2Step 2: Power down the robot and visually inspect the motor power cable along its entire length for visible damage, cuts, burns, or areas of cable sheath wear exposing conductors.
3Step 3: At the drive cabinet, disconnect the motor power cable connector X30 from the affected servo drive. Inspect pins for damage, corrosion, or burn marks. Clean contacts with electrical contact cleaner if oxidation is present.
4Step 4: Using a digital multimeter set to resistance mode, measure continuity between all three motor phase conductors (U-V, V-W, W-U) at the drive-side connector. All readings should be below 2 ohms and balanced within 0.3 ohms of each other.
5Step 5: Measure insulation resistance from each motor phase to ground (cable shield) using a 500VDC megohmmeter. Readings should exceed 10 megohms. Values below 1 megohm indicate winding or cable insulation failure requiring replacement.
6Step 6: If cable and motor test good, the servo drive power stage has failed. Replace the affected servo drive module and perform drive commissioning procedure in WorkVisual including EMD measurement and mastering data verification before returning to operation.

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