KUKA KR C4 Smallsize-2 Debugging Guide

The US2 function must be checked in the following situations: after initial startup or re debugging, after robot changes, after safety configuration changes, after software updates, and after replacement of load voltage contactors. In the automatic variant, press the enable switch, the contactor is engaged, and the robotic arm can move; Release the enable switch and disconnect the contactor. Under the external PLC variant, the "Peripheral contactor (US2)" input check in the PROFIsafe/CIP Safety telegram can be cancelled. Under the KRC variant, the operation safety device can be turned on in automatic or automatic external mode, or the enable switch can be released for inspection in T1/T2. If the USS 2 option is used, the USS 2 status signal must be checked before starting the peripheral device.

Equipotential, transportation, and power on: Small cabinets should also be treated as large systems

The equipotential connection includes a 4 mm ² cable between the robotic arm and the controller; An additional equipotential cable of 4 mm ² is recommended between the central PE row and the controller PE connection. If a drive box is installed on KR C4 smallsize-2, a 16 mm ² PE conductor must be used between the drive box and the workshop equipotential; No additional 4 mm ² cable is required between the controller and the workshop equipotential. Before powering on, check the automatic power-off protection conditions in section 18.2 of EN 60204-1.

During transportation, the controller must be powered off, have no cable connections, the cabinet door must be closed, and the cabinet must be upright. Use 4 M8 DIN 580 lifting rings and lifting frames to slowly lift, move, and lower. It can also be transported by pallet trucks. Casters are only used for rolling inside the cabinet row and cannot be transported over long distances, let alone towed by forklifts or electric vehicles. The transportation of casters requires a flat and unobstructed ground, otherwise there is a risk of tipping.

ESD regulations must be followed before powering on. The installation must be horizontal and maintain the minimum spacing. Check whether the transportation damage, insurance, contactors, and boards are tightened, whether the modules are loose, and whether the screws and clamping connections are reliable. The operator must cover the 'Read manual' warning label with a local language label. After connecting the motor cable, data cable, external shaft cable, and peripheral cable, plug in X305 and connect X1 power supply. If the system configuration changes, it must be reconfigured using WorkVisual. The startup mode can only be used when external safety devices have not been installed or put into operation, and warning tapes, fences, or signs must be set up to ensure that no one is in the danger zone.

Module replacement: Same type can be replaced, but different models must be reconfigured

If the replacement is KCB, KSB, or KEB equipment of the same type, it can be replaced. Any number of KCB, KSB, and KEB devices can be replaced until all devices are simultaneously replaced by devices of the same type. But it is not possible to exchange two identical KCB components at the same time, only one of them can be exchanged at the same time. If changing to a different model, adding or removing devices, replacing hard drives, or installing a new KSS, the WorkVisual configuration system must be used.

After replacing the data cable, it is necessary to re master or perform a mastering test, otherwise incorrect position data may cause unexpected movement. After replacing the safety module, it is necessary to check the safety configuration, checksum, and safety axis monitoring function. If the security configuration checksum changes, the safety axis monitoring function must be checked. After any security related modifications, functional testing should be conducted and the results recorded.

Common troubleshooting: Starting from the safety chain, power chain, and communication chain

Fault 1: The controller cannot be powered on. Check X1 power supply, main switch, fuse, CCU_SR power supply, X305 battery connector. If the control PC does not start, check the low-voltage power supply, motherboard, fan, and power button. If the main contactor does not engage, check whether the safety chain is closed, whether the E-STOP is released, and whether the X11 external E-STOP is consistent in both channels.

Fault 2: E-STOP cannot be reset. Check the smartPAD E-STOP, external E-STOP, X11 local/external E-STOP pins, dual channel status, safety door, and operational safety confirmation. If using Ethernet secure interface, check the PROFIsafe/CIP Safety/FSoe connection and input/output bytes. E-STOP not tested for more than 12 months may also affect the effectiveness of safety functions.

Fault 3: Loss of operation safety signal. Opening the safety door in automatic mode will trigger safety stop 1. When restoring, the safety gate must be closed and the dual channel confirmation button must be pressed outside the fence. The confirmation function may not be activated by default and needs to be set in the security configuration. Automatic closing of safety doors cannot replace manual confirmation.