What causes KUKA Robot alarm KRC0168?

BCO signal cable is disconnected, damaged, or has poor electrical contact at connectors. BCO solenoid valve or pneumatic actuator is malfunctioning or not responding to control signals. Incorrect BCO timing parameters configured in the controller or machine data settings. Sensor failure detecting BCO position feedback (T1/T2 limit switches not functioning). Communication error or signal propagation delay between controller and BCO hardware interface.

How do I fix KUKA Robot alarm KRC0168?

1. Verify all BCO signal cables and connectors are firmly seated and undamaged; inspect for corrosion or contamination 2. Test BCO solenoid valve operation manually using the teach pendant diagnostics or direct 24V supply test 3. Check sensor feedback signals (T1/T2 limit switches) using the digital I/O diagnostics in the KRC controller interface 4. Review and confirm BCO timing parameters in Machine Data (MD) match the mechanical specifications and adjust if necessary 5. Perform a full BCO cycle test in manual mode (T1/T2) to isolate whether the issue is mechanical, electrical, or software-related 6. If issue persists, backup and reload the controller configuration; if unresolved, contact KUKA service for BCO hardware replacement or recalibration

KUKA Robot codes

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KUKA Robot Controller

System · Basic

Alarm KRC0168

KUKA Robot KRC0168 - BLOCK SELECT : BCO REACHING IN T1/T2 REQUIRED

This alarm indicates that the Block Change-Over (BCO) signal has not reached the expected state (T1 or T2) within the required time window during block selection operations. The BCO mechanism, which enables seamless program block transitions, is failing to complete its synchronization handshake with the controller's timing gates.

KUKA RobotSystemBasic

KRC0168

KUKA Robot KRC0168 - BLOCK SELECT : BCO REACHING IN T1/T2 REQUIRED

BLOCK SELECT : BCO REACHING IN T1/T2 REQUIRED

Common Causes

BCO signal cable is disconnected, damaged, or has poor electrical contact at connectors
BCO solenoid valve or pneumatic actuator is malfunctioning or not responding to control signals
Incorrect BCO timing parameters configured in the controller or machine data settings
Sensor failure detecting BCO position feedback (T1/T2 limit switches not functioning)
Communication error or signal propagation delay between controller and BCO hardware interface

Troubleshooting Steps

1Verify all BCO signal cables and connectors are firmly seated and undamaged; inspect for corrosion or contamination
2Test BCO solenoid valve operation manually using the teach pendant diagnostics or direct 24V supply test
3Check sensor feedback signals (T1/T2 limit switches) using the digital I/O diagnostics in the KRC controller interface
4Review and confirm BCO timing parameters in Machine Data (MD) match the mechanical specifications and adjust if necessary
5Perform a full BCO cycle test in manual mode (T1/T2) to isolate whether the issue is mechanical, electrical, or software-related
6If issue persists, backup and reload the controller configuration; if unresolved, contact KUKA service for BCO hardware replacement or recalibration

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