Troubleshooting and Maintenance of KUKA KR C4 Control Cabinet

Maintenance cycle and inspection points

The maintenance work of KUKA KR C4 should be carried out on a periodic basis. At least every 2 years, clean the heat exchanger, KPP and KSP radiators, external fans, and low-voltage power supply radiators according to installation conditions and pollution levels. Replace the motherboard battery, control the PC fan, external fan, and internal fan every 5 years. The battery replacement cycle depends on the battery monitoring indication. The filter element of the pressure relief plug also needs to be replaced when it changes color, and the original color is white.

The output of SIB relay should be checked every 6 months to 1 year. When checking the local emergency stop output, press the local emergency stop device. When checking the operator safety confirmation output, set the mode to automatic or automatic external and turn on operator safety. When checking the peripheral connection output, set it to automatic or automatic external, turn on operator safety, and release the enable switch in T1 or T2 mode. If there are no error messages, the relay output is normal. For expanding SIB, it is also necessary to check the alarm space output, SafeOperation active output, and Robot referenced output. After maintenance is completed, a visual inspection should be conducted to confirm that fuses, contactors, plugs, and boards are securely installed, cables are undamaged, PE equipotential connections are reliable, and system components are not worn or damaged.

Fault diagnosis: LED and fuse

The LED on CCU is the first-hand information for diagnosis. The red LED of the fuse indicates that the fuse is damaged, and turning off indicates that it is normal. Check F17.3 when PWRS/3.3 V green is turned off; If the PWR/3.3 V is on and the PWRS/3.3 V is off, the CCU module may need to be replaced. STAS2 and STAS1 are orange safety node indicator lights, check F17.3 when turned off; 1 Hz flashing indicates normal operation, 10 Hz flashing indicates guidance phase, and when the fault code flashes, check the X309, X310, and X312 cables. FSoE green indicates the status of EtherCAT security protocol, off indicates inactive, constant light indicates running, and flashing indicates internal fault. 27 V, PS1, PS2, and PS3 are green power indicators, corresponding to main power, short-term battery backup, medium battery backup, and long-term battery backup, respectively. L/A green indicates physical connection, flashing indicates data traffic. RUNSION and RUNCIB green indicate the status of EtherCAT nodes.

CCU fuses include: F17.1 for contactor output 1 to 4, 5 A; F17.2 for CCU input, 2 A; F17.4 for CCU safety input, 2 A; F17.3 for CCU logic, 2 A; F306 for smartPAD power supply, 2 A; F302 for SIB power supply, 5 A; F3.2 for KPP1 logic with battery backup, 7.5 A; F3.1 for KPP1 brake without battery backup, 15 A; F5.2 for KPP2 logic, 7.5 A; F5.1 for KPP2 brake, 15 A; F22 for option power supply, 7.5 A; F4.1 for KPC with battery backup, 10 A; F4.2 for KPC fan/internal fan, 2 A F307 is a CSP power supply, 2 A; F21 is an RDC power supply, 2 A; F305 is a battery fed power supply, 15 A; F6 is a 24 V non battery backup US1, 7.5 A; F301 is a 24V battery free backup US2, 10A; F15 is an internal fan, 2 A; F14 is an external fan, 7.5 A; F308 is an internal power supply with external power supply and battery backup, 7.5 A. The same specifications must be used when replacing fuses.

RDC LED includes STA3、RUN、L/A1、L/A2、L/A3、STA4、PWR/3.3 V、FSoE、STA2、STA1、STA0。 CSP LED includes LED1 operation, LED2 sleep, LED3 automatic, LED4 to LED6 error. If all LEDs light up for 3 seconds after CSP is powered on, it indicates normal operation. Error states include: LED1 flashing slowly and LED4 on, indicating device or BIOS startup error, checking HDD/SSD, USB or replacing PC; LED5 on, indicating Windows or PMS startup timeout, replacing hard disk or reloading image; LED6 lights up to indicate waiting for RTS RUNNING timeout, reloading the image or running setup. In the LAN Onboard LED of the control PC, Activity/Link green indicates connection, and Speed yellow/green indicates 10 Mb, 100 Mb, or 1000 Mb. SIB LEDs include L/A, PWR_3V3, RUN, STAS2, FSoE, STAS1, PWRS 3.3 V, and fuse LEDs. The standard SIB fuse F250 is 4 A, and the extended SIB fuse F260 is 4 A. Semiconductor fuses can self reset, but should not be triggered frequently.

KPP/KSP Error Information Quick Check

In the error messages of KPP and KSP,% 1 represents the device type,% 2 represents the driver or power supply number, and% 3 represents the error code. Common errors include: 26031 internal error, reinitializing the driver bus and checking the KPP LED; 26032 IxT overload, check program load, machine, temperature, current trajectory, adjust speed; 26033 grounding fault, check the motor cable and motor; 26034 overcurrent, check the current trajectory, motor, and cable; 26035 Intermediate circuit overvoltage, check the trajectory of the intermediate circuit, main power supply, and braking resistor to reduce the braking load; 26036 intermediate circuit undervoltage, check the main power supply and intermediate circuit cables; 26037 logic power supply overvoltage, check 27 V power supply; 26038 logic power supply undervoltage, check 27 V power supply and battery; The temperature of device 26039 is too high. Check the fan inside the cabinet, ambient temperature, program load, cooling circuit, and PC fan; The temperature of the 26040 radiator is too high. Check the installation position, ventilation duct, and gap; 26041 motor phase loss, check motor cable and motor; 26042 communication error, check EtherCAT cable, stack CCU、KPP、KSP； 26045 hardware failure, reinitialize or replace the device; 26046 main power supply phase loss, check the power cord and KPP wiring; 26047 power failure, check if the power supply is below 300 V; 26048 charging overvoltage, check the main power supply voltage and module quantity; 26050 brake resistor fault, check the brake resistor and wiring; 26051 chopping overload, reducing frequent braking overload; 26130 intermediate circuit charging failed, check the intermediate circuit cable; 26132 brake fault, check the brake voltage, motor/brake, and brake cable. Warning messages are similar to error messages, but of lower severity.