Kuka KR C2 User Manual
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Kuka KR C2 User Manual

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See also: Operating Handbook
CONTROL CABINET
KR C2 - - USA
edition2005
User Manual
Fault Analysis / Diagnosis
Issued: 20 Dec 2004
Version: 00
BetrHbKRC2FL- -USA- -Fehler 11.04.00 en
1 of 86

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  • Page 1 CONTROL CABINET KR C2 - - USA edition2005 User Manual Fault Analysis / Diagnosis Issued: 20 Dec 2004 Version: 00 BetrHbKRC2FL- -USA- -Fehler 11.04.00 en 1 of 86...
  • Page 2 Copyright 2004 KUKA Roboter GmbH Zugspitzstrasse 140 D- -86165 Augsburg This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in the case of a replacement or service work.

  • Page 3: Table Of Contents

    ............. . . Repair by KUKA service personnel .
  • Page 4 User Manual 3.6.3 No entries can be made via KCP ..........3.6.4 EMERGENCY STOP cannot be acknowledged .
  • Page 5 11.1.2 Oscilloscope screen ............11.1.3 The information window .
  • Page 6 User Manual 6 of 86 BetrHbKRC2FL- -USA- -Fehler 11.04.00 en...

  • Page 7: Repair And Procurement Of Spare Parts

    Repair and procurement of spare parts Repair and procurement of spare parts Repairs to the KR C may only be carried out by KUKA customer support personnel or by customers authorized to do so after participation in a relevant KUKA Robot Group service seminar.

  • Page 8: Fault Analysis And Elimination

    User Manual Fault analysis and elimination The following procedure is recommended for isolating the cause of the fault and enabling effective repair of the KRC: Fault analysis Is the fault reproducible? -- Permanent fault -- Sporadic fault Did the fault occur after installation or conversion? -- Transportation damage -- Commissioning faults Did the fault occur during operation?

  • Page 9: Typical Fault Profiles

    Typical fault profiles Typical fault profiles Fault profiles related to the PC 3.1.1 Power supply The motherboard and drives are supplied with power by an integrated switched--mode power supply. Typical power supply fault profiles are: -- Supply voltage that is characterized by dropouts or spikes -- Output voltage overload -- Output voltage failure -- Internal overheating due to fan failure...

  • Page 10: Fault Profile Checklist

    User Manual 3.1.5 Fault profile checklist Main switch on PC to “ON”, system fails to boot, display stays dark, power supply fan and CPU fan do not work Possible causes: -- Power supply defective -- Short circuit on the motherboard -- Short circuit on a connected device Elimination of fault: -- Disconnect all devices from the power supply unit.
  • Page 11 Typical fault profiles (continued) System boots normally, display stays dark Possible causes: -- KVGA defective -- KCP2 connecting cable snapped -- 24 V supply voltage for KCP2 not present in MFC3 Elimination of fault: -- Exchange KVGA -- Exchange KCP2 connecting cable (KVGA to X19) -- Exchange connecting cable (X3) from the ESC--CI board to the MFC (X807) -- Exchange safety logic System crash when booting, no keyboard entries possible...
  • Page 12 User Manual BIOS error message “CMOS Checksum Error” Possible causes: -- Undervoltage in lithium battery on the motherboard -- Incorrect or missing entries in CMOS setup -- CMOS memory on motherboard defective Elimination of fault: -- Replace lithium battery -- Check entries in CMOS setup and correct if necessary -- Exchange PC rack BIOS error message “MEMORY TEST FAILED”...
  • Page 13 Typical fault profiles (continued) Cannot access floppy disk drive (FDD) Possible causes: -- CMOS setup: FDD type not correctly entered or FDD controller deactivated -- FDD data cable and power supply not connected correctly -- FDD defective -- FDD interface on motherboard defective Elimination of fault: -- Check CMOS settings and correct if necessary -- Connect data cable and power supply correctly...
  • Page 14 -- Exchange MFC -- Remove expansion card and run controller up again -- Exchange PC rack KUKA HMI does not boot and is aborted with a General Protection fault Possible causes: -- Defective files in the software installation -- Settings in CMOS setup incorrect...

  • Page 15: Fault Profiles Related To Dse And Machine Data

    -- If the machine data are incorrect, copy the correct machine data from the CD into the directory C:\KRC\Roboter\KRC\mada. With KUKA HMI active, the machine data are overwritten again during the Power Off backup. -- Exit the HMI beforehand, by means of EXIT, or -- Carry out a controlled exit from the boot sequence and change the machine data BetrHbKRC2FL- -USA- -Fehler 11.04.00 en...

  • Page 16: The Drives Cannot Be Switched On

    If there is an encoder error, the controller cancels the RC Ready signal on the MFC and the brakes are applied. -- Is there a KSD (KUKA Servo Drive) error message present? Certain errors (e.g. overcurrent, overvoltage) cause the servo drive module to deactivate the drives automatically.

  • Page 17: Dse Error Messages When Booting The System

    Typical fault profiles (continued) DSE error messages when booting the system 3.3.1 DSE x not found The MFC checks whether a DSE is connected. If no connected DSE is detected, the error message “DSE x not found” is generated. The loading of the machine data is canceled. The following follow--up message is generated: “DSE axis assignment Ax, machine data loader canceled, erroneous %1 machine data”.

  • Page 18: Dse Axis Assignment Ax

    User Manual 3.3.4 DSE axis assignment Ax Either the error is merely a follow--up message or the axis assignment with $DSECHANNEL is incorrect. Possible causes: -- DSE, MFC defective (follow--up message) -- $DSECHANNEL incorrect axis assignment 3.3.5 Power module axis Ax not / incorrectly connected The current calibration of the axes is compared with the value $CURR_CAL in the machine data list.

  • Page 19: Dse Error Messages During Operation

    Typical fault profiles (continued) DSE error messages during operation 3.4.1 Watchdog interpolation cycle Ax The interpolator sends one feed value per interpolation cycle to the DSE. If this transmission is interrupted for one or more cycles, the watchdog is triggered and this error message is generated.

  • Page 20: Fault Profiles Related To The Mfc

    User Manual Fault profiles related to the MFC 3.5.1 Controller hangs when loading software components Possible causes: -- MFC cannot be initialized -- MFC incorrectly connected -- Additional expansion card (e.g. Interbus) interfering with functioning of MFC -- PCI bus on motherboard faulty Elimination of fault: -- Remove expansion card and run controller up again -- Check for correct fit of MFC...

  • Page 21: Operating Mode Switchover On Kcp Does Not React

    Typical fault profiles (continued) 3.5.4 Operating mode switchover on KCP does not react Possible causes: -- Mode detection on MFC defective -- Mode selector switch on KCP, cable or connector faulty Elimination of fault: -- Exchange MFC -- Exchange KCP -- Exchange ESC board 3.5.5 When PC is booted, the operating system VxWorks does not run up...

  • Page 22: Fault Profiles Related To The Kcp

    User Manual Fault profiles related to the KCP 3.6.1 No display on the LCD Possible causes: -- Connecting cable defective -- KVGA defective -- KCP defective Elimination of fault: -- Exchange connecting cable -- Exchange KVGA -- Exchange KCP 3.6.2 Drives cannot be switched on Possible causes: -- Connecting cable defective...

  • Page 23: Emergency Stop Cannot Be Acknowledged

    Typical fault profiles (continued) 3.6.4 EMERGENCY STOP cannot be acknowledged Possible causes: -- EMERGENCY STOP button defective -- Connecting cable defective Elimination of fault: -- Exchange KCP -- Exchange connecting cable 3.6.5 Space Mouse does not work Possible causes: -- Connecting cable defective -- Space Mouse defective -- MFC defective (CAN bus) Elimination of fault:...

  • Page 24: Fault Profiles Related To A Field Bus Card

    User Manual Fault profiles related to a field bus card 3.7.1 Communication via diagnostic interface not possible Possible causes: -- Data cable, periphery faulty -- Diagnostic interface on field bus card defective Elimination of fault: -- Take appropriate measures on data cable, periphery -- Exchange field bus card 3.7.2 Error message “xxxxx I/O driver configuration error”...

  • Page 25: Servo Drive Module Messages And Error Displays

    Servo drive module messages and error displays Servo drive module messages and error displays In the event of a drives error, messages are displayed in several ways. Servo drive module LEDs (KSD1) The operating state of the KSD is indicated by two LEDs on the front. Fig.

  • Page 26: Kcp Messages For Drives Diagnosis

    User Manual KCP messages for drives diagnosis The following KSD error messages are displayed in the message window of the KCP. Display in Meaning/ Troubleshooting/ message window cause of error possible fault elimination DRIVES ERROR KSD is in a fault state; robot carries See detailed error message which is Ax No.: TRIP out Emergency Stop.

  • Page 27: Kps- - 600 Messages And Error Displays

    KPS- -600 messages and error displays KPS- - 600 messages and error displays KPS- -600/10 and /20 LED indicators There are six LEDs on the front of the KPS--600. LED 1 (red) and LED 2 (green) indicate internal states of the KPS. LED 3 (green) and LED 4 (green) are reserved for the safety logic and are not yet assigned.

  • Page 28: Meaning Of Leds 1 And 2

    User Manual 5.1.1 Meaning of LEDs 1 and 2 LED 1 (red) LED 2 (green) Priority* Meaning Processor without power supply Flashes at 1.5 Hz Intermediate circuit voltage < 60 V Intermediate circuit voltage > 60 V Flashes at 6 Hz Communication error Flashes at 3 Hz Brake error...

  • Page 29: Kps--600 Error Messages On The Kcp

    KPS- -600 messages and error displays (continued) 5.1.4 KPS- -600 error messages on the KCP Display in message window Meaning/cause of error Troubleshooting/ possible remedy Parameter error PMx Checksum error in Restart/exchange KPS checksum parameter set 1 Parameter error PMx Checksum error in the control Restart/exchange KPS Control...
  • Page 30 K1 contactor welded PMx Main contactor K1 stuck Exchange KPS The mastering can be saved manually via the KUKA HMI. Before changing the battery: Setup > Master > Save current data 30 of 86 BetrHbKRC2FL- -USA- -Fehler 11.04.00 en...

  • Page 31: Kps- -27 Operating State Indicators

    KPS- -27 operating state indicators KPS- - 27 operating state indicators On the front of the KPS--27 are two LEDs which indicate the operating states of the low--volt- age power supply unit: LED indicator State Meaning Green LED (OK) Normal operation Red LED (overload) Overload operation Red LED (overload)

  • Page 32: Dse- -Ibs Operating State Indicators

    User Manual DSE- - IBS operating state indicators When the DSE--IBS is plugged in, the green diagnostic LED is on the upper side. The mean- ing of the LEDs is explained in the following table: Green LED Meaning Servo program not active Error Flashing Servo program active –...

  • Page 33: Rdc2 Operating State Indicators

    RDC2 operating state indicators RDC2 operating state indicators There are two diagnostic LEDs on the RDC2. The meaning of the LEDs is explained in the following table: LED indicator State Meaning No power supply Green LED Green LED 3.3 V power supply OK Flashing RDC not yet ready (boot procedure) Red LED...

  • Page 34: Esc Diagnostic Tool

    The ESC diagnosis window is then displayed. The type and number of nodes available de- pend on the periphery used. Fig. 4 Example: KR C2 standard configuration with KCP, KPS--600, MFC and CI board 34 of 86 BetrHbKRC2FL- -USA- -Fehler 11.04.00 en...

  • Page 35: Softkey Bar

    ESC diagnostic tool (continued) The safety circuit units present are shown in the display. The passive MFC node is not dis- played. The CI board does not have a node. The current node is highlighted by means of a selection frame (focus). Special node states are indicated in color.
  • Page 36 User Manual Information about the selected node. Entries can be made using the softkey “Setup”. List of all errors that have occurred. Description of the selected error. At Expert level, certain settings can be made for a specific node using the softkey “Setup”. Global settings for the following entries: Path of the icons used Node color in event of error (default “red”)

  • Page 37: Esc Diagnosis Error Messages

    ESC diagnostic tool (continued) Safety circuit diagnosis display Corrective measure Byte timeout during receipt of log Check bus wiring Checksum error in log Check bus wiring Invalid header byte Check bus wiring Interface error Check bus wiring Mode error Both operating modes active Only one operating mode may be selected.
  • Page 38 User Manual Safety circuit diagnosis Corrective measure display Cross--connection error at: Short--circuit TA24(A) / TA24(B). Check wiring of Enabling switch 2 the input for enabling switch 2 panic position (ZS2). Cross--connection error at: Short--circuit TA24(A) / TA24(B). Check wiring of Activate drives or Drives enable the input for Activate drives (AA) and Drives enable (AF).

  • Page 39: Dse- - Rdw Diagnostic Tool

    DSE- -RDW diagnostic tool DSE- - RDW diagnostic tool This service option offers you a range of options for displaying states and fault diagnosis as well as for configuring the DSE--RDW part of the robot system. 10.1 Main menu of the DSE- -RDW diagnostic tool Navigate within the menus using the mouse, or use the keypad to enter the number preced- ing the menu text.

  • Page 40: Language Selection

    User Manual 10.1.1 Language selection The language for the menus is selected via: DSE--RDW > Language > [desired language]: Display in the status line: Version number of the DSE--RDW diagnostic tool Type of control cabinet Current value of the DSE interrupt counter: incrementation of the counter indicates that the DSE control program is running correctly.

  • Page 41: System Info

    Displays the operating state of the DSE. Display box assignment: Driver state: program is being executed Control type: type of controller (KR C1, KR C2, KR C3) MFC: version of the MFC module used 1. DSE: type of the first DSE module...

  • Page 42: Mfc2 Register Display

    User Manual 10.1.3 MFC2 register display Displays the contents of the MFC register. Display box assignment: MFC: version of the MFC module used Remaining display boxes: development data Softkey assignment: Start continuous display Start / stop the continuous updating of the display Refresh Triggers a one--off update of the display 42 of 86...

  • Page 43: Dse Ibs Information

    10.1.4 DSE IBS information Displays DSE hardware and software versions. Display box assignment: Control type: type of controller (KR C1, KR C2, KR C3) DSE hardware: hardware version of the DSE DSE Clock Speed: clock frequency of the DSE used Remaining display boxes: internal version numbers BetrHbKRC2FL- -USA- -Fehler 11.04.00 en...

  • Page 44: Display Rdc Table

    User Manual 10.1.5 Display RDC table Displays RDC measurement and configuration data. Softkey assignment: Start continuous display Start / stop the continuous updating of the display Refresh Triggers a one--off update of the display Export Saves the current RDC table to the hard drive Page up / Page down Navigation within the table Data concerning the hardware configuration of the RDC are listed in the table from line 88...

  • Page 45: Rdc Offset And Symmetry Adjustment

    DSE- -RDW diagnostic tool (continued) 10.1.6 RDC offset and symmetry adjustment Displays the adjustment data for all axes. Adjustment of the following values is carried out automatically. Sine offset Cosine offset Sine calibration Cosine calibration In order to be able to determine the sine and cosine values correctly, every axis must have been moved through several revolutions of the motor.

  • Page 46: Check Rdc--Dse Communication

    User Manual 10.1.7 Check RDC- -DSE communication The RDC sends data words to the DSE in a 125 µs cycle. This function can be used to check the communication between the DSE and the RDC. Meaning of the values displayed in the message window: Order: The last command the DSE has sent to the RDC.

  • Page 47: Drive Bus Diagnostics

    DSE- -RDW diagnostic tool (continued) 10.1.8 Drive bus diagnostics The values displayed in the message window have the following meaning: Number of cycles: number of data transmissions between DSE and RDC since system switched on / reset Data errors: number of data errors in the data transmissions between DSE and RDC (sporadic errors) Data errors in series: number of consecutive data errors following the first three Ident errors: number of errors during transmission...

  • Page 48: Drive Bus Error List

    User Manual 10.1.9 Drive bus error list Displays the error statistics with the drive bus running. Softkey assignment: Start continuous display Start / stop the continuous updating of the display Refresh Triggers a one--off update of the display Reset cycle counter Reset errors Reset error list 48 of 86...

  • Page 49: Drive Bus Diagnostics -- Kps--2

    DSE- -RDW diagnostic tool (continued) 10.1.10 Drive bus diagnostics - - KPS- -2 Softkey assignment: Start continuous display Start / stop the continuous updating of the display Refresh Triggers a one--off update of the display Export code table Saves the current code table to the hard drive (example: C:\KRC\Roboter\Log\Drivebus1--4_KSD1--8.log) Meaning of the values displayed in the message window: Lecom error...

  • Page 50: Drive Bus Ksd 1--16

    User Manual 10.1.11 Drive bus KSD 1- -16 Softkey assignment: Start continuous display Start / stop the continuous updating of the display Refresh Triggers a one--off update of the display Export code table Saves the current code table to the hard drive (example: C:\KRC\Roboter\Log\Drivebus1--4_KSD1--8.log) Meaning of the values displayed in the message window: Lecom error...

  • Page 51: Error Messages Valid For The Kps--600

    DSE- -RDW diagnostic tool (continued) 10.1.12 Error messages valid for the KPS- -600 IBS trip number Lecom error Message text Meaning number “ok” Device state OK “Pr1- -Trip” Checksum error in parameter set 1 “HO5- -Trip” Checksum error in the control unit device set “CCr- -Trip”...

  • Page 52: Error Messages Valid For The Ksds

    User Manual 10.1.13 Error messages valid for the KSDs (valid from Firmware V0.3 onwards) IBS trip number Lecom error Message text Meaning number “ok” Device state OK “Pr1- -Trip” Checksum error in parameter set 1 “HO5- -Trip” Checksum error in the control unit device set “CCr- -Trip”...

  • Page 53: Oscilloscope

    Oscilloscope Oscilloscope The submenu “Oscilloscope” contains the two additional menu items “Display” and “Configure”. Using the menu key “Monitor”, open first the submenu “Diagnosis” and then the menu “Oscilloscope”. The following submenu is displayed: The commands in the menu bar are deactivated and cannot be selected while the oscillo- scope is being displayed or configured.

  • Page 54: File Selection

    User Manual 11.1.1 File selection The desired file can be selected using the arrow keys. The name of the selected file is indicated by a color highlight. Move the cursor to a file having the end digit “1”. It contains data from the digital servoelectronics DSE (“3”...

  • Page 55: The Information Window

    Oscilloscope (continued) White Active color: White The “active” color is permanently displayed at the bottom left of the screen. You can “move” through the entire trace by using the arrow keys. You can exit the display function again at any time by pressing the softkey “Cancel”. 11.1.3 The information window Now press the softkey “Info”.

  • Page 56: The Softkey Bar

    User Manual 11.1.4 The softkey bar The softkey bar has four levels in the function “Display”. You can switch between these four levels by using the softkey “===>”. 11.1.5 The color softkeys To make it as easy as possible to read the display, a maximum of eight different colors (blue, green, white, red, magenta, brown, yellow and cyan) are shown.

  • Page 57: The Scaling Function

    Oscilloscope (continued) 11.1.6 The scaling function In the display, you are able to increase or reduce the amplitude of individual curves. To do so, press the softkey “Channel” until the color of the desired curve is active. The active color is permanently displayed at the bottom left of the window. Active color: Blue Now observe what changes occur when you press the keys “M”...

  • Page 58: The Zoom Function

    User Manual 11.1.7 The zoom function Press the softkey “===>” repeatedly until the following softkey bar appears. When the softkey “Zoom” is pressed, a white cross about five millimeters high appears in the middle of the window. This can be moved about the entire window using the arrow keys. Move it to the position of your choice and then press the Enter key.
  • Page 59 Oscilloscope (continued) Blue Green White Magenta Brown Cyan Yellow Evaluation of RMS Active color: Magenta Now move this line to the start point of your r.m.s. value evaluation using the “←” and “→” arrow keys and then press the Enter key. You can now use the “←”...

  • Page 60: Print

    User Manual 11.1.10 Print If you would like to print out the contents of the screen, please press the softkey “Print”. The screen is printed on the current default printer of the operating system; the printer should be set to “Landscape”. 11.1.11 The cursor functions Press the softkey “===>”...
  • Page 61 Oscilloscope (continued) The value that the selected curve had at the time where the cursor is currently positioned is displayed at the top left of the window (two values are displayed in this illustration as the softkey “Filter off” has been selected). When inputs or outputs are displayed, the bit pattern of the selected input or output group is displayed.
  • Page 62 User Manual The values for the second cursor now appear to the right of the display for the first cursor. Two values are displayed in this illustration, one below the other, as the softkey “Filter off” has been selected. When inputs or outputs are displayed, the bit pattern of the selected input or output group is shown here as well.

  • Page 63: The Filter Function

    Oscilloscope (continued) Green Blue White Magenta Brown Active color: Magenta The values for the second cursor now appear to the right of the display for the first cursor. The difference between these two cursors is displayed on the left--hand side. These cursors can be removed again by pressing the softkey “HCursor1”...

  • Page 64: Superposing Traces

    User Manual 11.1.13 Superposing traces To allow you to compare data from different traces with each other, the function “2nd file” has been integrated. To do this, open the menu using the menu key “Monitor”. Then select “Diagnosis”. The following submenu is displayed: As you want to use the oscilloscope function “Show”...
  • Page 65 Oscilloscope (continued) After selecting this file, please press the softkey “2nd file”. Beneath the trace file list appears 2nd file the message “BEW31.TRC marked for second file, please choose first file and hit “Ok”. Now use the arrow keys to move the cursor to a file with the end digit 1, for example. After selecting this file, please press the softkey “Ok”.

  • Page 66: Changing Color Assignments

    User Manual 11.1.14 Changing color assignments The color assignments of the individual curves can be changed at any time. This is necessary, for example, if more than 8 channels are assigned and not all channels can be displayed simultaneously because there are only 8 colors available. To do so, open the information window by pressing the softkey “Info”.

  • Page 67: Switching Curves On And Off

    Oscilloscope (continued) 11.1.15 Switching curves on and off It can sometimes be necessary to completely remove individual curves from the display. To do so, open the information window by pressing the softkey “Info”. Select the curve that you would like to remove from the display. The curve that is currently selected is highlighted by a color background.

  • Page 68: Configure

    User Manual 11.2 Configure Before you can record something with the oscilloscope, you must first tell it WHAT and HOW it is to record. For this purpose, the oscilloscope function offers a range of configuration options. A window is opened on the display. Data which characterize the trace in greater detail must be entered here.
  • Page 69 Oscilloscope (continued) The various input boxes can be selected using the “←” and “→” arrow keys. Then enter the desired values by means of the keyboard or numeric keypad. If you only wish to change a few of the characters in the selected entry, press the “↓” or “↑”...

  • Page 70: General

    User Manual 11.2.1 General The name and length of the trace are specified in this window. Name of recording A file name under which the trace will be saved later can be defined here. Do not use more than seven characters because a further digit is added to the file name by the system in order to distinguish different types of trace.

  • Page 71: Trigger Condition

    Oscilloscope (continued) 11.2.2 Trigger condition The position in time and the trigger condition for the trace are specified in this box. Pre- -Trigger Specify the position in time of the trace in relation to the trigger time in this box. The value between 0% and 100% that is entered refers to the programmed trace length.
  • Page 72 User Manual Trigger event In this field, select the event which will trigger recording. Trigger on I/O state The recording starts when the defined input/output assumes the specified state. The I/O and the state must be defined. Start by user, recording until buffer is full The recording must be initiated manually with the softkey “Start”.

  • Page 73: Trace Status

    Oscilloscope (continued) 11.2.3 Trace status The current working status of the oscilloscope can be seen in this field. Trace status Meaning #T_WAIT Trace is started and is waiting for the trigger condition. All of the data before the trace is triggered are recorded. #TRIGGERED Trace is triggered and runs for as long as specified in the boxes “Length of recording (sec)”...
  • Page 74 User Manual DSE (Digital Servo Electronics) card Here you can select if you want to record data of DSE 1 (axes 1--8) or DSE 2 (axes 9--16). If you do not want to record any DSE data at all, please select the option “No DSE data”. Files containing the traces of DSE data are identified by the end digit “1”...
  • Page 75 Oscilloscope (continued) Explanation of the individual values: Values to record Meaning Bus voltage PM1 Power module 1 Bus voltage PM2 Power module 2 Command value Command value from the interpolator per position control cycle Actual value Actual value per position control cycle Following error Difference between command position and actual posi- tion...
  • Page 76 This function is only available in “Expert” mode. Test data These data are analyzed by KUKA Roboter GmbH. If problems occur, the customer can contact KUKA Support and create a corresponding file for evaluation by KUKA. This function is only available in “Expert” mode.

  • Page 77: Examples Of A Trace

    Oscilloscope (continued) 11.2.5 Examples of a trace As the oscilloscope function with all the configuration and display options is complex, we want to introduce you to the use of this tool with the aid of a few examples. Example 1 The following are to be monitored: command speed of the drive of axis 1 actual speed of the drive of axis 1...
  • Page 78 User Manual Example 2 The signals of inputs and outputs 1 to 16 are to be recorded as soon as input 3 takes on the state “TRUE”. Entry Name Trace2 (max. 7 characters) Length of recording Pre--Trigger (%) Trigger on I/O state I/O state $IN : 3 = TRUE DSE card...
  • Page 79 Oscilloscope (continued) Example 3 A robot program branches to various subprograms depending on how the PLC sets specific signals. In a certain, unknown situation, the program branches to the subprogram “SP55.SRC”, which is not desired in this configuration, however. For the purpose of checking the I/O communication of the robot program with the PLC in this situation, an unassigned output (e.g.
  • Page 80 User Manual Example 4 You discover that a robot program always stops at night because an error occurs in the I/O communication with the PLC. It cannot be determined whether this error is caused by the PLC program or the robot program since nothing is known about the incorrect communica- tion at this point.

  • Page 81: Robot Repair Card

    Robot repair card Robot repair card You will be sent a Repair Card along with the spare parts requested from the KUKA Robot Group. Return the completed Repair Card to the KUKA Robot Group along with the defective exchange parts removed during the repair.
  • Page 82 Box E The serial number of the robot system can be found here: Fig. 7 Rating plate Box F The serial number of the control cabinet can be found here: KR C2 0122 00106204 2000 392.750- - 36... 3x400 V...
  • Page 83 Robot repair card (continued) Box G The serial number of the PC controller can be found on the front of the lower swing frame inside the control cabinet: For safety reasons, the cabinet door may only be opened by a qualified electri- cian.
  • Page 84 User Manual Box K Enter in this box the serial number and, if possible, the manufacturer’s release of the failed part. Box L Enter in this box the serial number and, if possible, the manufacturer’s release of the replacement part. Box M Enter here the duration of downtime and the time required, in minutes, for repairing the robot system.
  • Page 85 Robot repair card (continued) Box O Enter, in this box, the value displayed on the operating hours meter at the time of the fault. The number of operating hours can be obtained by dividing the value of the system variable $ROBRUNTIME by 60. In order to read this system variable, press the menu key “Monitor”...
  • Page 86 In this box, let us know your name and the date on which the repair card was completed. Please mark one of the two boxes to indicate whether you are a customer or an employee of the KUKA Robot Group. Box Q In this box you must specify the reasons for returning the part.
  • Page 87 Index Diagnostic tool, 40 Display, 53 Adjustment data, 45 DPRAM, 41 AE coil, 37 Drive bus, 48 Article numbers, 7 Drive bus diagnostics, 47 Axis load, 26 Drive bus diagnostics -- KPS--2, 49 Drive bus error list, 48 Drives diagnosis, 26 Ballast error, 28 Drives enable, 38 Ballast resistor, 28, 29, 30...
  • Page 88 KPS--27, 31 Panic position, 35, 38 KPS--600, 27 Parameter error, 29 KSD error messages, 26 PC rack, 7 KUKA service personnel, 7 PICA, 37 PICB, 37 Power unit, 26 Power--on time counter, 49, 50 Language selection, 40 Procurement of spare parts, 7...
  • Page 89 Index Repair card, 81 Repairs, 7 Test data, 76 Resolver position, 46 Toggle bit error, 26 RMS value function, 58 Robot brakes, 28 Trace status, 73, 78 Transportation damage, 8 Trigger condition, 71 Safety circuit, 34, 35 Trigger event, 72 Safety logic, 27 Typical fault profiles, 9 Safety system, 34...

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