What causes KUKA Robot alarm KRC0290?

Incorrect software limit configuration for endless axis in $CONFIG.DAT or axis parameters. Accumulated position error from continuous rotation without proper position feedback reset. Encoder or feedback sensor malfunction causing incorrect position data interpretation. Motion command with excessive distance or rotation beyond configured range boundaries. Loss of reference position or calibration drift on the endless axis after power loss or emergency stop.

How do I fix KUKA Robot alarm KRC0290?

1. Check the axis configuration in $CONFIG.DAT to verify that the endless axis limits are correctly set with appropriate min/max position boundaries 2. Perform a axis reference move (referencing) or recalibration for the affected axis using the KRC teach pendant to restore proper position feedback 3. Verify encoder/resolver health and wiring connections for the specific axis using KRC diagnostics or multimeter for signal continuity 4. Review the motion program logic and verify that commanded movements do not exceed the configured position range for endless axes 5. Check system logs in KUKA.log for preceding errors or feedback anomalies that may indicate sensor or drive faults 6. If issue persists, reset controller parameters to factory defaults and recalibrate all axes, then perform a complete motion test cycle

KUKA Robot codes

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KUKA Robot Controller

Servo/Axis · Basic

Alarm KRC0290

KUKA Robot KRC0290 - STOP DUE TO VALUE OUT OF RANGE OVERFLOW, <motion direction> <axis number>

This alarm occurs when an endless (continuous) axis, typically a rotational axis like the wrist or external axis, exceeds its maximum position value range and causes an overflow condition. The robot controller detects that the actual axis position has surpassed the configured software limits, triggering an immediate motion stop to prevent mechanical damage or unpredictable behavior. The alarm indicates both the direction of motion (positive or negative) and the specific axis number where the overflow occurred.

KUKA RobotServo/AxisBasic

KRC0290

KUKA Robot KRC0290 - STOP DUE TO VALUE OUT OF RANGE OVERFLOW, <motion direction> <axis number>

STOP DUE TO VALUE OUT OF RANGE OVERFLOW, <motion direction> <axis number>

Common Causes

Incorrect software limit configuration for endless axis in $CONFIG.DAT or axis parameters
Accumulated position error from continuous rotation without proper position feedback reset
Encoder or feedback sensor malfunction causing incorrect position data interpretation
Motion command with excessive distance or rotation beyond configured range boundaries
Loss of reference position or calibration drift on the endless axis after power loss or emergency stop

Troubleshooting Steps

1Check the axis configuration in $CONFIG.DAT to verify that the endless axis limits are correctly set with appropriate min/max position boundaries
2Perform a axis reference move (referencing) or recalibration for the affected axis using the KRC teach pendant to restore proper position feedback
3Verify encoder/resolver health and wiring connections for the specific axis using KRC diagnostics or multimeter for signal continuity
4Review the motion program logic and verify that commanded movements do not exceed the configured position range for endless axes
5Check system logs in KUKA.log for preceding errors or feedback anomalies that may indicate sensor or drive faults
6If issue persists, reset controller parameters to factory defaults and recalibrate all axes, then perform a complete motion test cycle

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