What causes KUKA Robot alarm KRC0415?

Incorrect work envelope limits configured in the robot's system parameters or safety configuration file. Robot program contains waypoints or trajectories that extend beyond the defined workspace boundaries. Mechanical drift or calibration error causing the robot's actual position to deviate from commanded position. External tool or payload mounted on the end-effector extends beyond the envelope limits that were originally calculated. Damaged or misaligned robot structure (bent arm, loose joints) causing the robot to reach farther than normal kinematics would allow.

How do I fix KUKA Robot alarm KRC0415?

1. Stop the robot immediately and verify there is no collision or obstruction preventing normal operation 2. Review the active work envelope settings in the KRC controller's system configuration (System > Safety > Work Envelope) and compare against the actual robot installation layout 3. Run a diagnostic teach pendant jog test in manual mode to identify at which axis combination or position the alarm triggers 4. Verify the robot's calibration status and re-calibrate if necessary using the KRC calibration procedure to ensure accurate positional feedback 5. Inspect the robot's mechanical structure for visible damage, bent components, or loose connections that could alter the kinematic chain 6. Modify the program trajectory to keep all waypoints within the defined envelope limits, or expand the work envelope boundaries if the application requires extended reach and safety permits

KUKA Robot codes

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KUKA Robot Controller

System · Advanced

Alarm KRC0415

KUKA Robot KRC0415 - WORK ENVELOPE EXCEEDED

This alarm indicates that the robot's end-effector or a point on the manipulator has exceeded the programmed work envelope boundaries defined in the system configuration. The work envelope represents the maximum operational area that the robot is permitted to reach, and this violation is a safety-critical condition that halts all motion to prevent collisions with external equipment, fixtures, or facility structures.

KUKA RobotSystemAdvanced

KRC0415

KUKA Robot KRC0415 - WORK ENVELOPE EXCEEDED

WORK ENVELOPE EXCEEDED

Common Causes

Incorrect work envelope limits configured in the robot's system parameters or safety configuration file
Robot program contains waypoints or trajectories that extend beyond the defined workspace boundaries
Mechanical drift or calibration error causing the robot's actual position to deviate from commanded position
External tool or payload mounted on the end-effector extends beyond the envelope limits that were originally calculated
Damaged or misaligned robot structure (bent arm, loose joints) causing the robot to reach farther than normal kinematics would allow

Troubleshooting Steps

1Stop the robot immediately and verify there is no collision or obstruction preventing normal operation
2Review the active work envelope settings in the KRC controller's system configuration (System > Safety > Work Envelope) and compare against the actual robot installation layout
3Run a diagnostic teach pendant jog test in manual mode to identify at which axis combination or position the alarm triggers
4Verify the robot's calibration status and re-calibrate if necessary using the KRC calibration procedure to ensure accurate positional feedback
5Inspect the robot's mechanical structure for visible damage, bent components, or loose connections that could alter the kinematic chain
6Modify the program trajectory to keep all waypoints within the defined envelope limits, or expand the work envelope boundaries if the application requires extended reach and safety permits

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