KUKA KR C4 Midsize Fault Diagnosis

The LED of SIB includes L/A, PWR_3V3, RUN, STAS2, FSoE, STAS1, PWRS 3.3 V, and fuse LED. The standard SIB fuse F250 is 4 A, and the extended SIB fuse F260 is 4 A. The LED of RDC includes STA3、RUN、L/A1、L/A2、L/A3、STA4、PWR/3.3 V、FSoE、STA2、STA1、STA0。 CSP's LEDs include 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.

Fuses and error codes

The specifications of CCU fuses are as follows: 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, 7.5 A; F3.1 for KPP1 brake, 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, 10 A; F4.2 is a KPC fan, 2 A; F307 is a CSP power supply, 2 A; F21 is an RDC power supply, 2 A; F305 is battery fed, 15 A; F6 is a 24 V battery free 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, 7.5 A. The same specifications must be used when replacing fuses.

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.

Module replacement steps

When replacing the external fan, first unplug the fan connector X14, remove the rear panel, remove the fan bracket and fan, install a new fan and restore the connection. When replacing the internal fan, unplug the fan connector X962, remove the fastening screws of the fan module, install the new module and connect it. When replacing the control PC, unplug the power supply and all connections, loosen the rolling nut, and take out the PC along the guide rail; After installing a new PC, connect the network cable, start the controller, and test it. When replacing the control PC fan, it is necessary to open the PC casing, remove the fan grille, fan, and rivets, install a new fan, and restore it. When replacing HDD/SSD, disconnect the SATA and power connections, remove the knurled screws, install the new hard drive, install the operating system and KSS, and configure the system through WorkVisual. When replacing the LAN Dual NIC network card, open the PC case, unplug the connection, release the network card fixing, insert the new network card and fix it.

When replacing KPP, unplug all connections, unlock and unplug X20 and X21 data cables, loosen Allen screws, and remove KPP from the bracket; When installing the new KPP, hang it into the bracket and tighten the fastening screws with a torque of 4 Nm, then insert it back into the connection according to the label and lock X20 and X21. Replacing KSP is similar. When replacing the CCU, unlock the data cable connector, unplug all connections, remove the fixing plate, and take out the CCU; After installing the new CCU, insert it back according to the label and lock the connector. When replacing the SIB, unlock the data cable connector, unplug all connections, remove the fixing plate, install the new SIB, and insert it back according to the label. When replacing the RDC, disconnect all cables, remove the RDC box cover, unplug the EDS connection, remove the 4 TORX screws, and take out the RDC module; When installing a new RDC, thread the cable through the designated entrance and place it in the RDC box. Tighten the TORX screws in diagonal order to 2.0 Nm, connect the EDS, X15, X17, X18, X20, and rotary transformer cables X1 to X6, cover the box cover and tighten to 3.0 Nm. When replacing the battery, pay attention to the polarity, both battery blocks must be replaced at the same time, and check if the system variable $ACCU_STATE is # CHARGE.OK. When replacing the low-voltage power supply, unplug the connection, remove the rear panel, take out the power supply, install a new power supply, and restore the connection. When replacing the pressure relief plug, remove the foam ring, replace the filter element, and replace the foam ring. When replacing the main filter, remove the main switch and side panel, disconnect them, remove the grounding conductor, install a new filter, and restore it.