KUKA Sunrise Cabinet Next Generation Small 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 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; Turn off PS2 and check if X1 or controller is in Sleep state.

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, 2 A; F302 is unused, 5 A; F3-1 is unused, 15 A; F5-1 is unused, 15 A; F4-1 is a KPC with battery backup, 10 A; F307 is unused, 2 A; F4-2 is unused, 2 A; F22 is unused, 7.5 A; F5-2 is unused, 7.5 A; F3-2 is unused, 7.5 A; F17-2 is CCU_SR input, 2 A; F17-4 is CCU_SR safety input and relay, 2 A; F17-1 is CCU_SR contactor output 1 to 4, 5 A; F17-3 is CCU_SR logic, 2 A; F14 is unused Used, 7.5 A; F6 is 24 V with optional backup without battery, 7.5 A; F21 is PDS power supply, 3 A; F305 is battery fed, 15 A; F301 is backup without battery, 10 A; F15 is power fan, 2 A; F308 is external power supply, 7.5 A. Low voltage power supply unit fuse F1 is blown at 80 V, 5 A; F2 is blown at 80 V, 7.5 A. When troubleshooting, first check the fuse LED, Measure the voltage again and finally consider module replacement.

Common troubleshooting ideas

When there is no display when powered on, first check the power connection, main switch, X1 incoming line, and fuse to confirm whether the control PC is started. When the emergency stop cannot be reset, check whether the smartPAD emergency stop is released, whether the X11 external emergency stop circuit is closed, and whether the safety interface configuration is correct. When the operator's safety alarm is triggered, check whether the safety door is closed, whether the confirmation button is pressed, and whether X11 safety input 2 is normal. When the drive cannot be enabled, check the enable switch, external enable, safety stop 1 input, safety output, and CCU_SR LED. When the fan or temperature alarm occurs, clean the fan and heat sink, check the ambient temperature, and confirm that the ventilation duct is not blocked by filter cotton. When the battery alarm occurs, check the battery voltage and charging status, charge according to the storage temperature cycle, and replace the battery pack if necessary. When there is a communication failure, check the X65 EtherCAT, X66 KLI, X69 service interface, and motherboard LAN interface to confirm that the WorkVisual configuration is correct. When there is a safety output failure, check the PELV power supply, dual channel relay output, and external cross connections. Before any repair, the power must be cut off, labeled, and the voltage must be lowered to below 60 V, and ESD regulations must be followed.

Component replacement process

When replacing the motherboard, first turn off the controller and prevent restarting, disconnect the power, open the casing, unplug the fan connection, remove the fan bracket, remove the PC card, disconnect the motherboard connection, remove the Torx fixing screws, and place the motherboard on the ESD pad. After installing the new motherboard, restore all connections, fan racks, fan connections, and PC cards, and close the casing. When replacing the motherboard battery, open the casing, unlock the button battery locking mechanism, remove the old battery, insert 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.