KUKA KR C4 Smallsize-2 family's smallest control cabinet

Security interface X11 and US2 inspection

The X11 security interface is internally connected to CCU_SR, which is used for dual channel signals such as emergency stop, operator safety, safety stop 2, external enable, and safety operation stop. Test outputs A and B are pulse voltages that can only be used as safe inputs for the corresponding channels and cannot be used as regular power supplies. During dynamic testing, the test output is alternately turned off, with a turn off pulse length t1 of 625 μ s and a range of 125 μ s to 2.375 ms. The time t2 between two turn off pulses on the same channel is 106 ms, and the offset t3 between two turn off pulses on the same channel is 53 ms. The safety input must use floating contacts, and the input channel SIN_X_A must be powered by TA_S, while SIN_X_B must be powered by TA-B. The safety output is a dual channel floating relay output that can be connected to the upper level safety PLC. The wiring example can achieve category 3 and PL d.

X11 External Enable Switch: External Enable 1 must be pressed when T1 or T2 is tapped, and the input is closed; External enable 2 must not be in the panic position, input closed. If external enable 1 is not connected, short circuit 11/12 of channel A and 29/30 of channel B; External enable 2 is not connected, short circuit 13/14 of channel A and 31/32 of channel B. If smartPAD is connected, its enable switch performs AND logic with external enable. Inspection of the USS load voltage contactor: In the PROFIsafe or CIP Safety configuration, set the USS input and the contactor is engaged; Reset the US2 input and disconnect the contactor. In automatic mode, press the enable switch to close the contactor and move the robotic arm; Release the enable switch and disconnect the contactor. In KRC configuration, operator safety can be turned on in automatic or automatic external mode, or the enable switch can be released in T1/T2 to check. Cross connection must be prevented between US1 and US2, and it is recommended to separate wiring or use reinforced insulated cables.

CCU_SR LED diagnosis

The LED on CCU_SR is the first-hand diagnostic information. PHY4 and SW-P0 are green, constantly on or flashing indicates normal, and off indicates a fault. Usually, CCU_SR needs to be replaced. RUNSION green indicates the status of the EtherCAT safety node: normally on for normal operation, off for initialization, flashing at 2.5 Hz for Pre Op, single signal for Safe Op, flashing at 10 Hz for firmware update boot. L/A KSB, L/A KSB KPC-MC, L/A KCB, L/A KSB smartPAD, etc. Green or orange colors indicate physical connections and data traffic: green is always on for physical connections, off for unconnected, and flashing for data traffic; Orange represents 1 Gbit, green represents 100 Mbit. PWR/3.3 V, PWR/2.5 V, and PWR/1.2 V are green power indicators. When turned off, check the F17-3, X308 jumper plugs, F308, and external 24V power supply; If PWR/3.3 V is on and PWRS/3.3 V is off, consider replacing CCU_SR. When PWRS/3.3 V is turned off, check F17-3. If PWR/3.3 V is on, replace CCU_SR. STAS2 and STAS1 are orange safety node indicator lights: check F17-3 when they are off, and replace CCU_SR if PWR/3.3 V is on; 1 Hz flicker is normal, 10 Hz flicker is the guiding phase; When the fault code flashes, check the X309, X310, and X312 cables. You can disconnect these cables and restart the controller. FSoE green indicates EtherCAT security protocol: off indicates inactive, constantly on indicates running, flashing indicates internal fault. RUN CIB_SR green indicates EtherCAT I/O node: normally on for running, off for initialization, flashing at 2.5 Hz for Pre Op, single signal for Safe Op, flashing at 10 Hz for firmware update. STA1 is an orange microcontroller I/O node: check F17-3 when it is turned off, and replace CCU_SR if PWR/3.3 V is on; 1 Hz flashing is normal, 10 Hz flashing guides, flashing is a fault code.

CCU_SR fuse quick check

The red LED of the fuse indicates that the fuse is damaged, and turning off indicates that it is normal. The same specifications must be used when replacing. F306 is the smartPAD power supply, 2 A; F302 is the I/O board power supply, 5 A; F3-1 is the KPP_SR and KSP_SR brake without battery backup, 15 A; F5-1 is the 24 V without battery backup option, 15 A; F4-1 is the KPC with battery backup, 10 A; F307 is the UL light optional, 2 A; F4-2 is the 24 V with battery backup fan, 2 A; F22 is the 24 V without battery backup option, 7.5 A; F5-2 is the 24 V with battery backup option, 7.5 A; F3-2 is the KPP_SR and KSP_SR logic with battery backup, 7.5 A; F17-2 is the CCU_SR input, 2 A; F17-4 is the CCU_SR input, 2 A; U_SR safety input and relay, 2 A; F17-1 CCU_SR contactor output 1 to 4, 5 A; F17-3 CCU_SR logic, 2 A; F14 external fan optional, 7.5 A; F6 I/O board power optional, 7.5 A; F21 RDC power supply, 3 A; F305 battery feed, 15 A; F301 24 V No battery backup option, 10 A; F15 is the power fan, 2 A; F308 is the external power supply, 7.5 A. When troubleshooting, first check the fuse LED, then measure the voltage, and finally consider module replacement.

Drive unit and control PC maintenance