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KUKA Robot Controller
Overtravel/Limit · Advanced
KUKA Robot KRC0185 - HARDWARE LIMITSWITCH / +24V MISSING
The hardware limit switch monitoring interface has detected that a common input signal for hardware limit switches has been activated or is missing the 24V supply voltage. This safety-critical function prevents axis overtravel damage and indicates either a genuine limit condition or a wiring or power supply fault. The alarm must be cleared before robot motion can resume.
KRC0185
KUKA Robot KRC0185 - HARDWARE LIMITSWITCH / +24V MISSING
HARDWARE LIMITSWITCH / +24V MISSING
The hardware limit switch monitoring interface has detected that a common input signal for hardware limit switches has been activated or is missing the 24V supply voltage. This safety-critical function prevents axis overtravel damage and indicates either a genuine limit condition or a wiring or power supply fault. The alarm must be cleared before robot motion can resume.
Common Causes
- Hardware limit switch physically contacted due to axis overtravel or mechanical bind condition
- 24V power supply to limit switch circuit interrupted due to blown fuse or loose connector
- Faulty wiring between limit switch input module and KRC4 interface board causing false trigger
- Defective limit switch sensor providing constant ground signal instead of open contact state
- Interface module firmware corruption or calibration drift in the limit switch monitoring circuit
Troubleshooting Steps
- 1Immediately stop all robot motion and visually inspect all axes for mechanical obstructions or bind conditions
- 2Check the 24V power supply voltage at the limit switch input module terminals using a multimeter
- 3Verify all connector plugs between limit switches and the interface module are fully seated and locked
- 4Use Diagnosis menu on KUKA smartPAD to read the raw digital input states of the limit switch circuit
- 5Physically test each limit switch by manually triggering it to confirm proper electrical response
- 6If power and connections are confirmed good, replace the suspect limit switch or interface module and perform system re-calibration
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