What causes KUKA Robot alarm KRC0649?

BCO program is being executed in continuous mode instead of step mode. Step mode was disabled or not activated before BCO execution began. Incorrect program flow logic attempting to run BCO in automatic continuous mode. BCO object configuration expects step-by-step execution but robot is in run mode. Missing or incomplete step mode initialization before BCO block invocation.

How do I fix KUKA Robot alarm KRC0649?

1. Stop the current program execution and switch the robot to step mode via the teach pendant or control interface 2. Verify that step mode is properly activated before executing the BCO block containing operation 1603 3. Review the KRL program logic to ensure BCO execution is only called when step mode is confirmed active 4. Check the BCO object configuration and documentation to confirm step mode is actually required for operation 1603 5. Reset the alarm and restart the program in step mode, executing one step at a time until the BCO block completes 6. If the issue persists, contact KUKA support with the program listing and BCO configuration details

KUKA Robot codes

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KUKA Robot Controller

System · Basic

Alarm KRC0649

KUKA Robot KRC0649 - BCO run in step mode required 1603

This alarm indicates that a Block Commutation Object (BCO) operation requires the robot to be running in step mode rather than continuous execution mode. The system has detected an attempt to execute BCO functionality 1603 without the proper execution mode enabled, which is a safety or operational requirement for this specific commutation block operation.

KUKA RobotSystemBasic

KRC0649

KUKA Robot KRC0649 - BCO run in step mode required 1603

BCO run in step mode required 1603

Common Causes

BCO program is being executed in continuous mode instead of step mode
Step mode was disabled or not activated before BCO execution began
Incorrect program flow logic attempting to run BCO in automatic continuous mode
BCO object configuration expects step-by-step execution but robot is in run mode
Missing or incomplete step mode initialization before BCO block invocation

Troubleshooting Steps

1Stop the current program execution and switch the robot to step mode via the teach pendant or control interface
2Verify that step mode is properly activated before executing the BCO block containing operation 1603
3Review the KRL program logic to ensure BCO execution is only called when step mode is confirmed active
4Check the BCO object configuration and documentation to confirm step mode is actually required for operation 1603
5Reset the alarm and restart the program in step mode, executing one step at a time until the BCO block completes
6If the issue persists, contact KUKA support with the program listing and BCO configuration details

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