What causes KUKA Robot alarm KRC0204?

Robot axis has physically reached mechanical hardware limit switch due to incorrect programming or manual jogging beyond software limits. 24VDC power supply in control cabinet has failed, dropped voltage below threshold, or circuit breaker has tripped. Wiring break or disconnection in the series limit switch chain from robot base through all axes back to controller. Failed or misadjusted hardware limit switch on one of the robot axes A1 through A6. Insufficient 24VDC voltage due to overloaded power supply from excessive connected safety devices or short circuit condition.

How do I fix KUKA Robot alarm KRC0204?

1. Step 1: Check 24VDC power supply voltage at terminals in control cabinet using multimeter and verify output is between 22-26VDC under load 2. Step 2: Examine robot physical position and verify no axis is pressed against mechanical hard stop or appears overextended beyond normal range 3. Step 3: Access diagnostics on smartPAD under Display > Inputs/Outputs > System Inputs and identify which specific limit switch input shows triggered state 4. Step 4: Manually jog robot in opposite direction from triggered limit using reduced velocity override (T1 mode, 10 percent) to move away from limit position 5. Step 5: Inspect identified limit switch on robot axis for mechanical damage, proper adjustment gap (typically 1-2mm activation distance), and verify wiring connections at switch and in cable carrier 6. Step 6: If limit switches show open circuit with robot in normal position or 24VDC cannot be restored, check series wiring continuity through entire limit switch chain and replace faulty switches or repair cable damage

KUKA Robot codes

axismd.ai

KUKA Robot Controller

Overtravel/Limit · Intermediate

Alarm KRC0204

KUKA Robot KRC0204 - Hardware Limit Switch or +24V Missing

The controller has detected that one or more hardware limit switches on robot axes have been triggered, or the 24VDC supply voltage feeding the safety circuit and limit switches has fallen below acceptable levels. The robot is immediately stopped to prevent mechanical damage from overtravel. Motion is inhibited until the condition is cleared and robot is moved away from the limit position.

KUKA RobotOvertravel/LimitIntermediate

KRC0204

KUKA Robot KRC0204 - Hardware Limit Switch or +24V Missing

Hardware Limit Switch or +24V Missing

Common Causes

Robot axis has physically reached mechanical hardware limit switch due to incorrect programming or manual jogging beyond software limits
24VDC power supply in control cabinet has failed, dropped voltage below threshold, or circuit breaker has tripped
Wiring break or disconnection in the series limit switch chain from robot base through all axes back to controller
Failed or misadjusted hardware limit switch on one of the robot axes A1 through A6
Insufficient 24VDC voltage due to overloaded power supply from excessive connected safety devices or short circuit condition

Troubleshooting Steps

1Step 1: Check 24VDC power supply voltage at terminals in control cabinet using multimeter and verify output is between 22-26VDC under load
2Step 2: Examine robot physical position and verify no axis is pressed against mechanical hard stop or appears overextended beyond normal range
3Step 3: Access diagnostics on smartPAD under Display > Inputs/Outputs > System Inputs and identify which specific limit switch input shows triggered state
4Step 4: Manually jog robot in opposite direction from triggered limit using reduced velocity override (T1 mode, 10 percent) to move away from limit position
5Step 5: Inspect identified limit switch on robot axis for mechanical damage, proper adjustment gap (typically 1-2mm activation distance), and verify wiring connections at switch and in cable carrier
6Step 6: If limit switches show open circuit with robot in normal position or 24VDC cannot be restored, check series wiring continuity through entire limit switch chain and replace faulty switches or repair cable damage

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