Troubleshooting KUKA Sunrise Cabinet Med

RUNSION EtherCAT Safety nodes: When turned off, it is Init; when turned on, it is operational; when flashing at 2.5 Hz, it is Pre Op; when a single signal is Safe Op; when flashing at 10 Hz, it is boot.

L/A network LED: When turned off, it indicates no physical connection; when turned on, it indicates connection; and when flashing, it indicates data traffic.

PWR/3.3V, PWR/2.5V, PWR/1.2V: Off indicates no power supply. Check F17.3, X308 jumper, F308, and external 24V power supply. If the PWR/3.3V is on but there are other abnormalities, it may be necessary to replace the CCU_SR.

STAS1 and STAS2 orange: Off indicates no power supply, 1 Hz flashing indicates normal, 10 Hz indicates boot, and other flashing indicates fault codes. Check the X309, X310, and X312 cables, disconnect them if necessary, and restart the test.

FSoE green: Off indicates inactive, lit indicates running, flashing indicates fault code.

RUN CIB_SR EtherCAT AT μ C I/O node: The meaning of the state is similar to that of an EtherCAT node.

STA1 (CIB_SR), STA2 (FPGA node) orange: off indicates no power supply, 1 Hz is normal, 10 Hz boot, other flashing indicates internal fault code.

27 V, PS1, PS2, PS3 green: represent main power supply, short-term battery backup, medium time battery backup, and long-term battery backup, respectively. Check the X1 incoming line, drive bus shutdown status, Sleep status, etc. when turning off.

Temp Fault red: Illuminates to indicate that the R1 brake resistor is overheating. Check X501, control cabinet cooling, and temperature sensors.

PWR_+12V5 green: Off indicates a loss of power to the brake chopper. Check the X500 and low-voltage power connectors.

Fuse LEDs in red: When lit, it indicates a fuse malfunction and needs to be replaced.

Common fuses include: F306 for smartPAD power supply 2 A; F4-1 for KPC with battery backup 10 A; F17-2 for CCU_SR input 2 A; F17-4 for safety input and relay 2 A; F17-1 for contactor output 5 A; F17-3 for logic 2 A; F21 for PDS power supply 3 A; F305 for battery feed 15 A; F301 for battery free backup 10 A; F15 for power fan 2 A; F308 for external power supply 7.5 A. Power supply connection fuses F1 and F2 are 10 A 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 unit F1 is 5 A/80 V, and F2 is 7.5 A/80 V.

A typical fault tree can be established as follows: If the entire machine is without power, first check the X1 incoming line F1/F2、 Equipment switch and grounding neutral; SmartPAD has no display, check F306, X19, and SmartPAD cables; The safety circuit cannot be reset. Check X11 emergency stop, operation safety, external safety stop, enable switch, and F17-4; Abnormal output of contactor, check F17-1; Logical exception, check F17-3; PDS abnormality, check F21; The battery cannot be backed up. Check F305, battery block, and charging status; Fan abnormality, check F15 and fan connector; External power supply abnormality, check F308.

Special risks in medical integration

KUKA Sunrise Cabinet Med is aimed at medical device manufacturers and therefore must be evaluated under the IEC 60601-1 system. The interface isolation should meet at least 2 x MOOP and 1 x MOPP, corresponding to approximately 3.4 mm electrical clearance, 5.0 mm creepage distance, and 3000 V withstand voltage. The devices connected to the controller must meet the corresponding isolation requirements. Medical device manufacturers must verify the overall system leakage current and consider the requirements of the ME system.

The robot controller cannot come into contact with patients or be accessed by unauthorized personnel. If the medical product requires a sterile environment, additional casing or protection is required. The robot body and flange are not part of the application, but may come into contact with patients, and it is necessary to evaluate whether to handle them according to the B, BF, or CF application part in risk management. The robot body and media flange can meet the requirements of B-type application.

In addition, it is necessary to evaluate the risks of liquid accumulation and infection, discomfort caused by vibration, unexpected shutdowns, single fault safety, brake as a safety measure, pinch risk, sensor accuracy, strong magnetic field influence, unverified absolute accuracy risk, and PEMS access to IT networks. The braking test cannot be shut down by the system integrator, and the system will enforce regular execution. If not executed, the system will stop. Medical equipment manufacturers must incorporate brake testing into their application and maintenance plans.