KUKA KR C5 micro KSS troubleshooting

Pre power on inspection: visually inspect for no condensation or damage; Install strain relief plates; Connect equipotential; Connect motor cables, data cables, and power cables; Insert smartPAD; Configure and connect security interfaces XG11.1 and XG58 (must be plugged in and out when the controller is turned off); Connect Ethernet and EtherCAT interfaces; Connect optional interfaces. Power on steps: Release the emergency stop on the smartPAD, turn on the device switch, and control the PC to start. The startup sequence is recovery stick, external hard drive, and internal hard drive; If an external hard drive is detected, the internal hard drive will be disabled; If no external hard drive is detected, it will not automatically switch to an internal hard drive. The robot controller can only run with the connected smartPAD-2.

Functional testing must be performed: after all connected emergency stop devices are pressed, smartPAD displays that the emergency stop has been triggered and does not display any emergency stop device errors; After all enable switches are released in test mode, the robot stops without displaying any enable device errors; Press and hold the panic function of all enable switches for 3 seconds, and the robot will stop without any errors; Safety output shutdown capability test, after turning off and then turning on the controller, smartPAD does not display safety output errors; The brake test is performed on each axis during initial start-up and re commissioning, and every 48 hours during operation, unless otherwise specified in the risk assessment.

Maintenance and module replacement

Maintenance work must be carried out after the controller is turned off, tagged and locked, and the power cable is unplugged. After a power outage, there may be residual voltage of 60 to 800 V in the intermediate circuit for up to 5 minutes, and at least 5 minutes must be waited for. KSP、 Motor connectors and connected motor cables may remain energized. The homework must comply with ESD regulations. Maintenance table requirement: Conduct annual cyclic functional testing on operational safety and all emergency stop devices; Test all enable switches; Test external enabling devices; Test the Drives ready light before entering the danger zone each time; Clean the fan protective grille according to the degree of pollution; Replace the system board battery every 10 years. Check if the plug connection is secure and inspect all system components for wear or damage.

Module replacement includes: replacement of strain relief board, replacement of 19 inch mounting frame, replacement of SSD hard drive, replacement of system board battery, replacement of input fuse F1/F2, replacement of system board, replacement of interface board, replacement of TCA-OUT interface board, replacement of KSP-STA interface card. General steps: Turn off the device switch and unplug the power cable; Wait for 5 minutes; Open the shell cover; Disconnect the plug connection; Replace components; Install the housing cover and tighten with a torque of 0.6 Nm; perform a power on inspection. When replacing the system board, be careful not to damage it by connecting it to the power unit through a vertically installed connection board. When replacing the interface board, disconnect the ribbon cable X1000. After replacing the battery, you need to plug in the USB keyboard, enter the BIOS to set the date and time, load the default values, and perform a functional test. After replacing the SSD, it is necessary to check the settings and perform functional testing. Replace fuses F1/F2 with 10 A 250 V slow melting 5 × 20 mm. To replace TCA-OUT, remove 3 TX10 TORX screws. When replacing KSP-STA, it is necessary to remove 4 TX10 TORX screws and pay attention to the vertical connection plate.

Common troubleshooting: KSP alarm and CSP LED

KSP warning messages are the focus of investigation. 26103 internal error: reinitialize the driver bus, Power Off/On。 26104 IxT overload: When starting, the program load is too high. During operation, check the mechanical, temperature, and current trajectories, reduce the program speed, and check the CBS pressure and gearbox. 26105 Grounding Fault: Check the motor cable and motor. 26106 Overcurrent: Check the current trajectory, motor, and motor cable. 26107 Intermediate circuit overvoltage: Check the trajectory of the intermediate circuit, main power supply, and braking resistor to reduce the braking load. 26108 Intermediate circuit undervoltage: Check the trajectory of the intermediate circuit and the main power supply. 26112 radiator overheating: Check the fan, ambient temperature, program load, cooling circuit cleanliness, installation position, and ventilation gap. 26113 motor phase loss: Check the motor cable and motor. 26114 communication error: reinitialize the driver bus, check the EtherCAT cable and stack. 26118 Power phase loss: Check the power cord. 26119 power failure: Check the power cord and fuse. 26122 brake resistor fault: Check the brake resistor. 26123 Braking resistor overload: Reduce frequent braking overload and check the braking resistor. 26131 Intermediate circuit charging failure: Check the intermediate circuit cable, main power supply, and system impedance. 26133 brake fault: Check the motor/brake, brake cable/motor cable.