KUKA Sunrise Cabinet Med Medical Collaborative Robot Special Control Cabinet

STAS2 and STAS1 are orange safety node indicator lights: check F17.3 when they are off, and replace CCU_SR if PWR/3.3 V is on; 1 Hz flicker is normal, 10 Hz flicker is the guiding phase; When the fault code flashes, check the X309, X310, and X312 cables. You can disconnect these cables and restart the controller. FSoE green indicates EtherCAT security protocol: off indicates inactive, constantly on indicates running, flashing indicates internal fault. KSB smartPAD_SC green/orange indicates smartPAD connection. RUN CIB_SR green indicates EtherCAT I/O node: normally on for running, off for initialization, flashing at 2.5 Hz for Pre Op, single signal for Safe Op, flashing at 10 Hz for firmware update. STA1 is an orange microcontroller I/O node: check F17.3 when turned off, and replace CCU_SR if PWR/3.3 V is on; 1 Hz flashing is normal, 10 Hz flashing guides, flashing is a fault code. STA2 is an FPGA node: check the X1 incoming line when it is turned off, and replace CCU_SR if PWR/3.3 V is on. 27 V, PS1, PS2, PS3 are green power indicators: when 27 V is turned off, check whether X1 is at 27.1 V; when PS1 is turned off, check whether X1 or the drive bus is at BusPowerOff; Check if X1 or controller is in Sleep state when PS2 is turned off; PS3 turn off and check X1. STA1 (PMB_SR) is an orange microcontroller USB: check X1 when turned off, and replace CCU_SR if PWR/5V is on. PWR/5V is powered by the green PMB: check the 27.1 V of X1 when it is turned off. Temp Fault: red indicates that the ballast resistor R1 is overheating: off indicates no overheating, constant light indicates overheating. Check the X501 connection, control cabinet cooling, and temperature sensor. PWR+12V5 green indicates brake chopper power supply: check X500 connection and low-voltage power supply connection when turned off. The red color of Fuse LEDs indicates the status of the fuse: if it is off, it is normal; if it is constantly on, it is damaged. Replace the fuse with the same specification.

Fuses and Low Voltage Power Supply

When the CCU_SR fuse is damaged, the red LED next to it lights up. The replacement must use the same specifications. F306 is a smartPAD power supply, 32 V/2 A; F302 unused, 32 V/5 A; F3-1 unused, 32 V/15 A; F5-1 unused, 32 V/15 A; F4-1 is KPC with battery backup, 32 V/10 A; F307 unused, 32 V/2 A; F4-2 unused, 32 V/2 A; F22 unused, 32 V/7.5 A; F5-2 unused, 32 V/7.5 A; F3-2 unused, 32 V/7.5 A; F17-2 is CCU_SR input, 32 V/2 A; F17-4 is CCU_SR safety input and relay, 32 V/2 A; F17-1 is CCU_SR contactor output 1 to 4, 32 V/5 A; F17-3 is CCU_SR logic, 32 V/2 A; F14 unused, 32 V/7.5 A; F6 is a 24 V battery free backup option, 32 V/7.5 A; F21 is a PDS power supply, 32 V/3 A; F305 is battery powered, 32 V/15 A; F301 is a backup without battery, 32 V/10 A; F15 is a power fan, 32 V/2 A; F308 is an external power supply with 32 V/7.5 A. The power connection fuses F1 and F2 are 10A slow melting/250 V AC. The secondary fuse F21.1 of the DC/DC converter is 3 A/32 V DC. The low voltage power supply fuse F1 is 5 A/80 V, F2 is 7.5 A/80 V, and the red LED next to it indicates a fault. When troubleshooting, first check the fuse LED, then measure the voltage, and finally consider module replacement.

Component replacement process

When replacing the motherboard battery, first turn off the controller and prevent restarting, disconnect the power, open the casing, unlock the button battery locking mechanism, remove the old battery, install the new battery and lock it. When replacing the hard drive, open the casing, disconnect the power and data cables of the hard drive, remove the fixing screws, replace the hard drive with a new one, restore the connection and fix it. When replacing the battery pack, open the casing, loosen the Velcro strap, unplug the battery connection wire. Both battery blocks must be replaced at the same time, paying attention to polarity. G3.2 and G3.1 correspond to the positive and negative poles. Reinstall the Velcro strap and restore the connection. When replacing the fan, open the casing, remove the fixing screws of the fan bracket, unplug the fan connection, remove the inner and outer grilles, install the new fan, reinstall the fan bracket and connect it. Start the controller after replacement and observe for any abnormalities. Repairs can only be carried out by KUKA customer support or trained customers, and module repairs can only be completed by KUKA trained personnel. Original spare parts must be used, otherwise it may cause damage, premature wear, and module failure. After replacing components, functional testing must be conducted, especially for safety functions.