Troubleshooting

KUKA desktop doesn't power on (black screen)

Make sure all the cables are properly connected and keep rebooting until you hear the second fan turning on - the yellow monitor light will then turn to blue.

Nothing happens + "timout before FRI State reached GOOD or EXCELLENT" when starting StartDGM app

It's most likely an ethernet configuration issue. Make sure you can ping the robot ip and that you are using the right ethernet port.

Joint limits exceeded

Each robot joint as a maximum limit. When exceeding it, you'll hear a click sound from the robot, lights will turn red on the control panel and you might see something like "hardware limit exceeded..." in the logs.

• Switch to T1 control mode (turn key-switch)
• Click on the "LBR_iiwa_14_R..." tab from the control panel and go to "Joint positions"
• Press the gray button half. If the axis names on the right side are highlighted in white, you can control the joint positions and move them away from the joint limits using the "-/+" buttons on the right side of the panel.
• If you cannot move manually the joints as described above, you need to re-master the axis (go to mastering and follow the instructions for mastering)

Safety control warning "Position sensor not mastered"

The axis need to be mastered.

• Select RKF mode (use the key switch of the control panel)
• Select the iiwa robot tab (upper left) in the main menu
• Select Mastering . Keep the enabling switch (grey) pressed while mastering an axis Sometimes, mastering fails in which case, just reboot the robot and try again

Unable to master axis XXX : moving to pre-mastering position failed with time-out

Reboot the cabinet, un-master and re-master all axes starting from axis 7.

Safety control warning "Position sensor not referenced"

The "position sensor not referenced" warning does not seem to prevent mastering nor to have all green lights & operate the robot.

Unable to remaster axis + "intermediate circuit voltage too low"

If you are unable to remaster the axis after exceeding torque limits with the following error

And if you see something like that in the robot device status :

It means that a fuse is burnt in the low power supply (grey box inside the sunrise cabinet) . First identify which fuse is dead

• Get a multimeter and a screwdriver
• Switch off power, unplug the cabinet and open it (see p. 65 of the sunrise cabinet documentation)
• Remove the fuses (one pink F1 4A, one brown F2 7.5A, cf. p. 74 section 12.3 of the same document)
• Test them with the multimeter (continuity or ohms mode) The fuse looks like this (for instance the pink one / F1 4A)

Get a new fuse. Spare fuses are in the KUKA box on the shelf .

• Replace the fuse
• Close / replug everyhing and try to master again To order new spare fuses, use this reference .

CK_COMPOUND_RETURN_ERROR with "Wrong FRI session state in "Monitoring (Wait)" in setup phase of FRI motion"

It's a latency issue . You may also see in the DGM logs : permission denied on "dev/cpu_dma_latency"` The fix is simply to give permission sudo chown {username} /dev/cpu_dma_latency

Memory allocation errors

If you see mlockall failed: Cannot allocate memory when running the DGM, try to run with sudo -s.

If you see something like :

[foonathan::memory] Allocator foonathan::memory::new_allocator (at (nil)) leaked 400 bytes. 
[foonathan::memory] Allocator foonathan::memory::heap_allocator (at (nil)) leaked 33384 bytes.

make sure that you have a clean ros install (see ubuntu installation scripts)

binding port number 30200 failed!

Find process PID running on that port lsof -i :30200 Output :

COMMAND     PID USER   FD   TYPE DEVICE SIZE/OFF NODE NAME
dgm_iiwa_ 72687 root    5u  IPv4 434170      0t0  UDP *:30200

Kill it sudo kill -9 72687