KSS00404 is a safety stop error that typically occurs in Kuka robot controllers. It indicates a safety-related issue that has prevented the robot from continuing its operation.

The "KSS00404 Safety Stop Error" on a KUKA robot controller indicates that the robot has been brought to a stop due to a safety event or condition. This error typically triggers when one of the safety circuits or sensors detects an issue that requires the robot to halt operation immediately to prevent potential harm or damage.

Steps to Troubleshoot and Resolve:

1. Check Emergency Stop Buttons:

   • Inspect all emergency stop buttons connected to the robot system to ensure none are activated. This includes those on the controller, pendant, and any external panels.
   • If an E-stop has been pressed, reset it and clear the error.

2. Inspect Safety Gates and Fences:

   • Verify that all safety gates, fences, and other protective barriers around the robot are securely closed and not triggered.
   • If a gate was opened, close it properly, and then reset the safety system.

3. Check Safety Sensors:

   • Inspect all connected safety sensors (e.g., light curtains, pressure mats, laser scanners) to ensure they are functioning correctly and are not obstructed.
   • Test the sensors to confirm they are detecting correctly and are not falsely triggering the safety stop.

4. Inspect Safety Relays and Circuits:

   • Check the safety relays and circuits for any faults or wiring issues. Loose connections, faulty relays, or damaged wiring could be causing the safety stop.
   • If a fault is detected in the safety circuits, repair or replace the faulty components.

5. Verify Safety Configuration:

   • Review the safety configuration settings in the KUKA system software. Ensure that the safety parameters are correctly configured according to the setup of your work cell.
   • If recent changes were made to the safety settings, consider reverting to the previous configuration to see if the issue resolves.

6. Check Communication with Safety Devices:

   • Verify that the robot controller is maintaining proper communication with all connected safety devices, such as a safety PLC or safety sensors.
   • If there are communication errors, resolve any network or connection issues.