KUKA KR C5 micro debugging and troubleshooting

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: replacing strain relief board, replacing 19 inch mounting frame, replacing SSD hard drive, replacing system board battery, replacing input fuse, replacing system board, replacing interface board, replacing microSD card and internal SSD. 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.

Troubleshooting: System board LED and common problems

There is an LED on the system board that lights up in red when there is a malfunction, which can be seen through the opening of the cooling system air inlet. If the system board LED lights up red, the controller should be turned off, the power cable should be unplugged, and the cable should be stored out of sight and reach. Contact KUKA customer support.

Common problem troubleshooting: Controller unable to power on: Check device switch, fuse F1/F2, power cable, XD1 connection. Startup failure after power on: Check the recovery stick, external hard drive, and internal hard drive. If an external hard drive is detected, the internal hard drive will be disabled. If there is no external hard drive, it will not automatically switch. The safety stop cannot be cancelled: check the emergency stop device, enable switch, operation safety signal, external emergency stop, and safety interface configuration. CRR mode cannot be switched: check if the reason for stopping still exists, if so, it cannot be switched to CRR; If the cause disappears and there is no stop request within 4 seconds, it will automatically switch to T1. The enable switch is invalid: check the smartPAD enable switch, Commander enable switch, security configuration, and XG58 external enable connection. The drives ready light is not on: check the XG33 connection, drive enable signal, and safety controller. Communication interruption: Check if the XF1 to XF8 interfaces and KSI interface are mistakenly connected to the IT network, KLI interface, KEI interface, firewall rules, cable length, and shielding. Heat dissipation issues: Check the fan, protective grille, minimum spacing, and ambient temperature. Battery failure: Replace the system board battery every 10 years and set the BIOS date and time after replacement.