Kuka KR C2 edition05 Operating Instructions Manual Download Page 78

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V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en

KR C2 edition05

6.2

Transportation by pallet truck

Preconditions

The control cabinet must be switched off.

No cables may be connected to the control cabinet.

The door of the control cabinet must be closed.

The control cabinet must be upright.

The anti-toppling bracket must be fastened to the control cabinet.

Procedure

6.3

Transportation by fork lift truck

Preconditions

The control cabinet must be switched off.

No cables may be connected to the control cabinet.

The door of the control cabinet must be closed.

The control cabinet must be upright.

The anti-toppling bracket must be fastened to the control cabinet.

Procedure

Fig. 6-2: Transportation by pallet truck

Control cabinet with anti-toppling bracket

Control cabinet in raised position

Fig. 6-3: Transportation by fork lift truck

Control cabinet with fork slots

Control cabinet with transformer installation kit

Summary of Contents for KR C2 edition05

Page 1: ...V3 3 11 07 200 Issued 11 07 2007 Version 3 3 KUKA Robot Group Controller KR C2 edition05 Operating Instructions Industrial automation Elincom Group European Union www hmi4u com Russia www elinc ru...

Page 2: ...e case of a replacement or service work We have checked the content of this documentation for conformity with the hardware and software described Nevertheless discrepancies cannot be precluded for whi...

Page 3: ...scription of the KUKA Control Panel KCP 19 2 4 1 Front view 20 2 4 2 Rear view 21 2 5 KCP coupler optional 21 2 6 Electronic Safety Circuit ESC safety logic 23 2 6 1 ESC nodes 24 2 6 2 Overview of CI3...

Page 4: ...robot system 56 4 2 4 Safety information 56 4 3 Safety features 57 4 3 1 Overview of the safety features 57 4 3 2 ESC safety logic 57 4 3 3 Operator safety input 57 4 3 4 EMERGENCY STOP button 58 4 3...

Page 5: ...onnecting connector X11 82 7 10 Switching on the robot controller 82 7 11 Checking the direction of rotation of the external fan 83 8 Operation 85 8 1 Display and operator control elements of the KCP...

Page 6: ...ages and error displays 112 11 8 KPS 27 error messages 115 11 9 Error messages on the KSD 115 11 10 KCP coupler LED display optional 117 11 11 KCP coupler troubleshooting 119 11 12 DSE RDW diagnosis 1...

Page 7: ...ing ESC nodes 139 11 13 11 Selecting the display for signals 140 11 13 12 Selecting the properties of the ESC node 141 11 13 13 Assigning ESC nodes to a controller 142 11 13 14 Error messages and trou...

Page 8: ...8 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en KR C2 edition05...

Page 9: ...pictogram are relevant to safety and must be ob served Notes Notes marked with this pictogram contain tips to make your work easier or ref erences to further information 1 4 Terms used For optimal us...

Page 10: ...ver Digital Converter RoboTeam A number of robots whose continuous path motions are synchronized or both synchronized and geometrically coordinated SafeRobot Software and hardware components to replac...

Page 11: ...cting cables Software Options accessories 2 2 Overview of the robot controller The robot controller is used for controlling the following systems KUKA robots KMC External kinematic system The robot co...

Page 12: ...f the drive circuit Monitoring Parts of the ESC safety circuit Communication with external periphery other controllers host computers PCs network Overview The control PC includes the following compone...

Page 13: ...s Overview Fig 2 3 Overview of the control PC 1 PC 4 Drives optional 2 PC interfaces 5 Batteries 3 PC fan Fig 2 4 Control PC interfaces Item Interface Item Interface 1 PCI slots 1 to 6 2 3 2 PC slot a...

Page 14: ...ted with the following plug in cards 3 USB 2x 13 ST5 serial real time inter face COM 3 4 X804 Ethernet 14 ST6 ESC KCP etc 5 COM 1 serial interface 15 ST3 drive bus to KPS600 6 LPT1 parallel interface...

Page 15: ...t Plug in card 1 Interbus card FOC optional Interbus card copper optional LPDN scanner card optional Profibus master slave card optional LPCN ControlNet card optional CN_EthernetIP card optional 2 LPD...

Page 16: ...tion card MFC3 Description 2 different MFC3 cards are used in the robot controller according to the spe cific customer requirements MFC3 Standard MFC3 Tech Item Element Item Element 1 External connect...

Page 17: ...the DSE The MFC3 Standard card can accommodate a maximum of 2 DSE IBS C33 modules Interface to the CI3 safety logic Fan monitoring Fig 2 7 MFC3 card Item Connector Description 1 X2 Interface to the C...

Page 18: ...are used in the robot system in the case of more than 8 axes each RDC must be fitted with a DSE IBS C33 board Overview Connections LED 2 3 9 KUKA VGA card KVGA Description The KCP is connected to the...

Page 19: ...a controlled shutdown of the robot control ler in the event of a power failure They are backed up by the KPS600 2 4 Description of the KUKA Control Panel KCP Function The KCP KUKA Control Panel is th...

Page 20: ...KCP 1 Mode selector switch 10 Numeric keypad 2 Drives ON 11 Softkeys 3 Drives OFF SSB GUI 12 Start backwards key 4 EMERGENCY STOP button 13 Start key 5 Space Mouse 14 STOP key 6 Right hand status key...

Page 21: ...4 Enabling switch 2 Start key 5 Enabling switch 3 Enabling switch Element Description Rating plate KCP rating plate Start key The Start key is used to start a program Enabling switch The enabling swi...

Page 22: ...display optional page 117 Fig 2 12 KCP coupler LEDs and request button 1 Fault LED red KCP coupler 2 Request button with request LED green Fig 2 13 KCP coupler card Item Connect or Description 1 X7 R...

Page 23: ...ill The ESC system consists of the following components CI3 board KCP master KPS600 MFC passive node The ESC system with its node periphery replaces all the interfaces of a con ventional safety system...

Page 24: ...nfiguration Each node consists of two ESC chips A and B which monitor each other If no KCP coupler is used the ESC circuit will only function with the KCP con nected If the KCP is unplugged during ope...

Page 25: ...QE Qualifying input This signal is used for external axes or load ing stations If the signal is interrupted in Test mode the drives contactor drops out immedi ately E2 Special keys witch customer spe...

Page 26: ...n CI3 Standard 2 6 3 CI3 Standard board page 26 No Indicates the following states Local E STOP CI3 Extended 2 6 4 CI3 Extend ed board page 28 Yes Indicates the following states Operating modes Local E...

Page 27: ...external mode selector switches optional 6 X7 CAN connection I O board 7 X6 Internal external power supply and ESC cir cuit 8 X5 KCP connection 9 X21 KCP power supply and KCP CAN 10 X22 Peripheral in...

Page 28: ...reset button Connections Item Designation Description 18 KY1 ESC Reset button Fig 2 17 CI3 Extended board connections and relays Item Designation Description 1 X18 Interface to MFC3 CR safety signals...

Page 29: ...e for inputs and outputs 11 X1 Internal 24 V power supply 18 X31 Connection robot controller internal fan 19 X8 Connection of external controllers E STOP button on control cabinet 20 X16 Internal inte...

Page 30: ...ector switches optional 6 X7 CAN connection I O board 7 X6 Internal external power supply and ESC cir cuit 8 X5 KCP connection 9 X21 KCP power supply and KCP CAN 10 X22 Peripheral interface for inputs...

Page 31: ...wer supply to a 2nd RDC via X19A The following states of the ESC circuit are indicated Operating modes Drives ON Local E STOP The ESC circuit can be reset using the reset button 26 Connections The CI3...

Page 32: ...puts 14 X23 Safe RDC interface optional 15 X1 Internal 24 V power supply 22 X10 QE signals 23 X28 Multi power tap OUT1 optional 24 X27 Multi power tap DeviceNet on MFC optional 25 X29 Multi power tap...

Page 33: ...t circuit braking relays Brake switches in common for all 6 robot axes and separate for 2 external axes Interface to DSE IBS and servo drive modules Battery charging circuit disconnection of the backu...

Page 34: ...Customer interface Control PC KSD Intermediate circuit The KPS 600 supplies the energy to the intermediate circuit and includes Rectifier circuit Charging circuit Ballast circuit Discharging circuit M...

Page 35: ...5 X K1a Interface to the power board for the K1 auxiliary contacts internal 6 X2 Control connections K1 7 X6 24 V from low voltage power supply 8 X123 User interface 9 X110 Fan resistor monitoring 10...

Page 36: ...sages page 115 2 7 4 KUKA Servo Drive KSD Configuration The KSD incorporates Power output stage Current controller Item Fuse Value in A Circuit 1 F1 20 KPS600 power supply F2 7 KPS 27 power supply F3...

Page 37: ...rature monitoring Communication monitoring Sizes 2 sizes are used Size 1 BG 1 KSD 08 16 32 Size 2 BG 2 KSD 48 64 The designations 08 to 64 give the max current in amps Connections Fig 2 24 Servo drive...

Page 38: ...read throughout the entire power mains without mains filters 2 8 Cabinet cooling Description The control cabinet is divided into two cooling circuits The inner zone con taining the control electronics...

Page 39: ...he control cabinet consists as standard of connec tions for the following cables Power cable infeed Motor cables to the robot Control cables to the robot KCP connection The configuration of the connec...

Page 40: ...R C2 ed05 connection panel 1 X1 XS1 power supply connec tion 9 Optional 2 X20 motor connection 10 X19 KCP connection 3 X7 motor connection 11 X21 RDC connection 4 Optional 12 PE1 ground conductor to t...

Page 41: ...system without a grounded neutral this may cause malfunctions in the robot controller and material dam age to the power supply units The robot controller may only be operated with grounded neutral po...

Page 42: ...42 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en KR C2 edition05 2 9 2 KCP connector X19 Connector pin allocation...

Page 43: ...43 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en 2 Product description 2 9 3 Motor connector X20 axes 1 to 6 Connector pin allocation...

Page 44: ...44 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en KR C2 edition05 2 9 4 Motor connector X7 optional Connector pin allocation...

Page 45: ...1 axes 1 to 8 Connector pin allocation 2 10 Description of the mounting plate for customer components optional Overview The mounting plate for customer components is a mounting plate on the inside of...

Page 46: ...es optional 2 Mounting plate for customer components The drives project into the installation area of the mounting plate Designation Values Weight of installed components max 5 kg Power dissipation of...

Page 47: ...ing plate Rated power input Heavy duty robot Palletizer Press to press robot 13 5 kVA see rating plate Mains side fusing min 3x25 A slow blowing max 3x32 A slow blowing see rating plate RCCB trip curr...

Page 48: ...illation 4 120 Hz 4 120 Hz Acceleration shock in X Y Z direction 10 g 2 5 g Waveform duration shock in X Y Z direction Half sine 11 ms Half sine 11 ms Supply voltage 26 8 V DC Main processor See shipp...

Page 49: ...ot controller 3 4 Minimum clearances robot controller Digital inputs 24 V DC pulsed resistive load only Dimensions 147 mm x 73 mm Fig 3 1 Dimensions in mm 1 Cooling unit optional 3 Side view 2 Front v...

Page 50: ...cabinet door Swing range standalone cabinet Door with computer frame approx 180 Swing range butt mounted cabinets Door approx 155 3 7 Plates and labels Overview The following plates and labels are att...

Page 51: ...V3 3 11 07 2007 KRC AD KRC2ed05 BA en 3 Technical data Fig 3 4 Plates and labels The plates may vary slightly from the examples illustrated depending on the specific cabinet type or as a result of up...

Page 52: ...rning sign 2 Hand injury warning sign 3 Discharging time warning 4 KR C2 ed05 rating plate 5 Reference to operating instructions 6 PC rating plate 7 Start up warnings on the door Grounded neutral Chec...

Page 53: ...ured that the installation site floor wall ceiling has the required grade of concrete and load bearing capacity The principal loads acting on the mounting base are indicated in the specifica tions Rob...

Page 54: ...tic mode The message on the control panel must be acknowledged Other safety equipment Other safety equipment must be integrated into the system in accordance with the corresponding standards and regul...

Page 55: ...that has been set STOP 0 STOP 1 and STOP 2 are the stop definitions according to EN 60204 2 Robot 5 Braking distance 3 Braking distance Trigger T1 T2 AUT AUT EXT EMERGENCY STOP pressed Path oriented...

Page 56: ...ional components tools software etc not supplied by KUKA Robot Group may be integrated into the robot system The user is liable for any damage these components may cause to the robot system Stop react...

Page 57: ...modes Qualifying inputs 4 3 3 Operator safety input The operator safety input is used for interlocking fixed guards Safety equip ment such as safety gates can be connected to the dual channel input I...

Page 58: ...g modes the drives are deactivated after 1 s and the robot stops with a STOP 1 The EMERGENCY STOP button must be pressed as soon as persons or equipment are endangered Before operation can be resumed...

Page 59: ...imitation option Most robots can be fitted with mechanical axis range limitation in main axes A1 to A3 The adjustable axis range limitation systems restrict the working range to the required minimum T...

Page 60: ...is only for use in exceptional circumstances and emergencies e g for freeing people After use of the release device the affected motors must be exchanged Procedure 1 Switch off the robot controller an...

Page 61: ...4 4 Personnel User The user of a robot system is responsible for its use The user must ensure that it can be operated in complete safety and define all safety measures for personnel System integrator...

Page 62: ...h it is unable to move on its own whether the payload is mounted or not If this is not possible the robot must be secured by appropriate means KCP The KCP must be removed from the system if it is not...

Page 63: ...ger zone of the robot during the function test The following must be checked during the function test The robot system is installed and connected There are no foreign bodies or destroyed loose parts o...

Page 64: ...r be liable to fall off The following safety measures must be carried out if programming in the dan ger zone of the robot The robot must only be moved at reduced velocity max 250 mm s In this way pers...

Page 65: ...application the robot type the technology packages used and other customer specific circumstances For this reason the overview does not claim to be comprehensive Step Description Information 1 Electro...

Page 66: ...RC AD KRC2ed05 BA en KR C2 edition05 5 3 Installation conditions Dimensions Minimum clearances Fig 5 1 Dimensions in mm 1 Cooling unit optional 3 Side view 2 Front view 4 Top view Fig 5 2 Minimum clea...

Page 67: ...ame approx 180 Swing range butt mounted cabinets Door approx 155 5 4 Connection conditions Power supply connection Fig 5 3 Minimum clearances with top mounted technology cabinet 1 Top mounted cabinet...

Page 68: ...ip current difference 300 mA per robot controller univer sal current sensitive Equipotential bonding The common neutral point for the equipotential bonding conductors and all protective ground conduc...

Page 69: ...on between X1 2 on the robot con troller and the power supply 5 5 2 Power supply connection via CEE connector XS1 Description With this option the robot controller is connected to the power supply via...

Page 70: ...edition05 5 6 EMERGENCY STOP circuit and safeguard The following examples show how the EMERGENCY STOP circuit and safe guard of the robot system can be connected to the periphery Example Fig 5 6 Power...

Page 71: ...into consideration when wiring interface X11 System concept Safety concept Various signals and functions are available depending on the specific CI3 board 2 6 2 Overview of CI3 boards page 25 Fig 5 8...

Page 72: ...72 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en KR C2 edition05 Connector pin allocation...

Page 73: ...STOP max 24 V 600 mA In the non activated state the contacts are closed Local E STOP channel B 2 3 External E STOP channel A 4 E STOP dual channel input max 24 V 10 mA External E STOP channel B 22 En...

Page 74: ...oup Automatic 48 46 Floating contacts of the safety circuit signal the operating mode These contacts are only availa ble if a CI3 Extended or CI3 Tech board is used Automatic contact 48 46 is closed i...

Page 75: ...KR C2 ed05 4 Cable duct 2 Equipotential bonding from the connection panel to the cable duct 5 Equipotential bonding from the cable duct to the robot 3 Connection panel KR C2 ed05 6 Equipotential bond...

Page 76: ...76 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en KR C2 edition05...

Page 77: ...Attach the lifting tackle with or without a lifting frame to all 4 transport eye bolts on the control cabinet 2 Attach the lifting tackle to the crane 3 Slowly lift and transport the control cabinet...

Page 78: ...dure 6 3 Transportation by fork lift truck Preconditions The control cabinet must be switched off No cables may be connected to the control cabinet The door of the control cabinet must be closed The c...

Page 79: ...Install the robot controller 7 2 Installing the robot con troller page 80 7 Connect the connecting cables 7 3 Connecting the connect ing cables page 80 8 Connect the KCP 7 4 Connecting the KCP page 81...

Page 80: ...red 21 Calibrate the tool In the case of a fixed tool calibrate external TCP 22 Enter load data 23 Calibrate base optional In the case of a fixed tool calibrate workpiece optional 24 If the robot is t...

Page 81: ...he robot controller 5 8 PE equipotential bonding page 74 2 Carry out a ground conductor check for the entire robot system in accord ance with DIN EN 60204 1 7 6 Connecting the robot controller to the...

Page 82: ...connecting connector X11 Procedure 1 Configure connector X11 in accordance with the system and safety con cepts 2 Connect interface connector X11 to the robot controller 7 10 Switching on the robot co...

Page 83: ...are 7 11 Checking the direction of rotation of the external fan Procedure Check outlet 2 on the rear of the robot controller Information about operator control of the robot using the KCP can be found...

Page 84: ...84 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en KR C2 edition05...

Page 85: ...riant to be coupled must be the same as that which was un coupled Fig 8 1 KCP coupler LEDs and request button 1 Fault LED red KCP coupler 2 Request button with request LED green Caution The KCP must n...

Page 86: ...the robot controller from a USB stick Precondition Robot controller is switched off External keyboard Procedure 1 Plug in bootable USB stick 2 Switch on the robot controller 3 Press F10 during the bo...

Page 87: ...nds on installation conditions and degree of fouling however no later than every 2 years Clean fan for outer cooling circuit with brush 15 2 Clean heat ex changer with brush 15 Clean heat sink with br...

Page 88: ...hat no cleaning fluid enters electrical components Do not use compressed air during cleaning work Procedure 1 Loosen and vacuum up any dust deposits 2 Clean robot controller with a cloth soaked with a...

Page 89: ...lug X11 Connector pin allocation The service jumper plug X11 is a Harting connector with a male insert type Han 108DD housing size 24B Caution The jumper plug is only to be used during start up and tr...

Page 90: ...om the fan plate 3 Tilt the fan plate downwards together with the fan 4 Unplug the fan connector 5 Pull the fan plate forwards to remove it 6 Note the fan installation position direction of rotation 7...

Page 91: ...crews from the fan holder 6 Take off the fan with the holder 7 Install the new fan 8 Plug in the fan connector and fasten the cable 9 Mount the rear cabinet panel and fasten 10 4 Exchanging the pressu...

Page 92: ...nd secured to prevent unau thorized persons from switching it on again Back up must be completed The power cable must be de energized Observe the ESD guidelines Procedure 1 Open the control cabinet do...

Page 93: ...guidelines Procedure 1 Remove the cable strap 2 Unplug the fan connector 3 Note the fan installation position direction of rotation 4 Remove the fan retaining screws 5 Take off the fan with the fan g...

Page 94: ...secured to prevent unau thorized persons from switching it on again Back up must be completed The power cable must be de energized Observe the ESD guidelines Procedure 1 Open the PC cover 2 Using your...

Page 95: ...nnection cables 3 Press the spring clamp to the left 4 Take out both battery blocks 5 Insert the new battery blocks and lock them in place with the spring clamp 6 Plug in the battery connection cables...

Page 96: ...n the control cabinet door 2 Remove the fastening screw of the drives holder 3 Push the drives holder out to the left 4 Disconnect the power supply and data cable 5 Remove the fastening screws at the...

Page 97: ...3 Push the drives holder out to the left 4 Disconnect the power supply and data cable 5 Remove the fastening screws at the side 6 Push the floppy disk drive out of the holder 7 Push the new floppy dis...

Page 98: ...nect the interface and power supply cables 7 Place the hard drive on the holder and fasten it with the retaining clip 8 Close the PC housing and the control cabinet door 9 Install the operating system...

Page 99: ...completed The power cable must be de energized Observe the ESD guidelines Procedure 1 Open the control cabinet door 2 Open the PC chassis 3 Unplug the connections to the MFC3 and DSE IBS C33 4 Release...

Page 100: ...ocedure 1 Open the control cabinet door 2 Unplug all connections to the KPS600 3 Slacken the Allen screws 4 Lift the KPS600 slightly tip the top forwards and lift the KPS600 out of the holder 5 Insert...

Page 101: ...ent unau thorized persons from switching it on again The power cable must be de energized Observe the ESD guidelines Wait 5 minutes until the intermediate circuit has discharged Procedure 1 Open the c...

Page 102: ...switched off and secured to prevent unau thorized persons from switching it on again Back up must be completed The power cable must be de energized Observe the ESD guidelines Procedure 1 Open the cont...

Page 103: ...ir Card is supplied with the exchange parts The Repair Card must be completed and returned to the KUKA Robot Group Effects Causes Remedy PC does not boot Display is dark Power supply defective Disconn...

Page 104: ...r supply not correctly con nected Connect power supply correctly CD ROM drive defective Exchange the CD ROM drive CD ROM drive cannot be read BIOS fails to detect CD ROM drive Load KUKA default settin...

Page 105: ...mode detection on MFC3 defective Exchange the MFC3 Mode selector switch on the KCP defective Replace KCP When PC is booted the operat ing system VxWorks does not run up MFC3 defective Exchange the MF...

Page 106: ...Check the configuration Field bus card cannot be initial ized Exchange field bus card Incorrect configuration of the file IOSYS INI Check entries in IOSYS INI After inserting the field bus card no di...

Page 107: ...toring for F16 9 LED4 red Fuse monitoring for F12 10 LED2 red Fuse monitoring for F13 11 LED14 green 24 V without battery back up 12 LED9 green 24 V with battery back up 13 LED15 green 5 V ESC nodes 1...

Page 108: ...es ON 6 F14 4 24 V DC drives ON 7 F15 7 5 24 V DC drives ON 8 F10 3 24 V DC VCC ESC 9 F23 2 RDC supply Item Designation Description 10 LED16 red Fuse monitoring for F2 11 LED5 red Fuse monitoring for...

Page 109: ...bus local ESC node error 27 LED21 green ESC bus local ESC node OK 28 LED19 red ESC bus KPS error 29 LED20 green ESC bus KPS OK Item Designation Description Fig 11 3 CI3 Bus board fuses and LEDs Item D...

Page 110: ...ut battery back up 18 LED9 green 24 V with battery back up 19 LED1 red Fuse monitoring for F10 20 LED12 red Fuse monitoring for F23 21 LED17 green ESC bus KCP OK 22 LED23 red ESC bus SafetyBUS Gateway...

Page 111: ...g for F14 7 LED8 red Fuse monitoring for F15 8 LED14 green 24 V without battery back up 9 LED29 green Voltage monitoring 3 3 V for CR PLDs 11 LED1 red Fuse monitoring for F10 12 LED11 red Fuse monitor...

Page 112: ...600 LED display and fuses 1 LED 1 red 7 Fuse F5 2 LED 2 green 8 Fuse F1 3 LED 3 red 9 Fuse F3 4 LED 4 red 10 Fuse F4 5 LED 5 green 11 Fuse F2 6 LED 6 green Design ation Rating Circuit F2 15 A 24 V DC...

Page 113: ...of current through the ballast resistor Flashes 4 times at 1 5 Hz 5 Ballast error Flashes 3 times at 1 5 Hz 6 Overvoltage in intermediate circuit Flashes 2 times at 1 5 Hz 7 Overtemperature in interi...

Page 114: ...tilation defective Cabinet temperature too high PMx Overtemperature inte rior Cabinet ventilation defective Drives error PMx no 79 Communication error with the EEPROM in the control unit Restart Excha...

Page 115: ...ake cable Brake error Ax PMx channel x Brake error external axes Brakes not con nected Short circuit on brake cable Intermediate circuit charging circuit defec tive PMx Optocoupler for bal last resist...

Page 116: ...oltage UIC default value 250 V Flashes quickly UIC Ulimit Off Flashes slowly UIC Ulimit Off Flashes quickly UIC Ulimit Off On Servo enable UIC Ulimit Display in message window Meaning cause Remedy DRI...

Page 117: ...Hardware monitoring Ground fault software monitoring Check motor cable Check motor FAILURE OF MOTOR PHASE Ax Motor phase failure Check motor cable Check motor Drives error Ax no 105 Checksum error in...

Page 118: ...prox 1 Hz Internal ESC communications error Flashes quickly approx 10 Hz ESC protocol timeout from KCP Item State Meaning 2 On KCP coupled and KCP coupler opera tional Off KCP uncoupled Flashes slowly...

Page 119: ...ct KCP variant and switch on the robot controller KCP disconnected without prior request Adhere to correct procedure 8 1 1 Uncoupling the KCP page 85 8 1 2 Coupling the KCP page 85 KCP disconnected be...

Page 120: ...c tool The Esc key takes you up a level in the menu structure Pressing the Esc key at the top menu level exits the DSE RDW diagnostic tool The following parameters are displayed The contents of the EE...

Page 121: ...o select MFC3 Display register Description The following parameters are displayed 2 DSE There is no second DSE present in this case The 4 display boxes are the same as for the first DSE Status line Ve...

Page 122: ...FC register display Parameter Description MFC Version of the MFC module used Address section RTACC Internal data Address sesction 82C54 Timer Revision number Reserved area Binary Input Input ESC0 Inpu...

Page 123: ...e displayed Data concerning the hardware configuration of the RDC are listed in the table from line 88 onwards Fig 11 12 DSE IBS information Parameter Description Control type Type of controller KR C2...

Page 124: ...ine calibration Cosine calibration Description The following parameters are displayed Fig 11 13 RDC table Softkey Description PgDn Moves down one line in the table PgUp Moves up one line in the table...

Page 125: ...RDC2 Check communication Description The following parameters are displayed Fig 11 14 RDC offset and symmetry Parameter Description 1 RDC2 offset und symme try Displays all adjustment data for the axe...

Page 126: ...8 Error Encoded display of the encoder error bits and EMT signals Checksum Checksum for all transferred data Axes 1 to 8 Displays the resolver position of axis nn The values vary during operation If a...

Page 127: ...cription Fig 11 17 Drive bus diagnostics Parameter Description Number of cycles Number of data transmissions between DSE and RDC since system switched on reset Data errors Number of data errors in the...

Page 128: ...he error statistics are displayed with the drive bus running Softkeys 11 12 10Drive bus KPS Procedure Under System info select 1 Drive Bus 01 KPS 2 Fig 11 18 Drive bus error list Softkey Description S...

Page 129: ...nd temperatures of the KPS Operating time counter Intermediate circuit has been active for xx hours Power on time counter KPS has been active for xx hours 1 and 2 code position Polling of the current...

Page 130: ...of production Date Serial number Number Software version Software version Rated current Maximum current Intermediate voltage Device load Heat sink temperature Polar wheel angle Voltages currents and t...

Page 131: ...50 CH Trip Overtemperature heat sink 39 52 CH2 Trip Overtemperature interior 24 79 Pr5 Trip Communication error with the EEP ROM in the control unit 28 65 CE4 Trip Max permissible number of com munica...

Page 132: ...in the ESC diagnosis tool IBS trip num ber Lecom error number Message text Description 0 0 ok Device state OK 1 72 Pr1 Trip Checksum error in parameter set 1 3 105 HO5 Trip Checksum error in the cont...

Page 133: ...editor 11 13 3 ESC circuit reset Procedure Reset the ESC circuit by pressing the Reset softkey Description The ESC circuit can be reset after an error The Reset softkey is only avail able if CI3 and M...

Page 134: ...In the event of an error the display automatically switches to the error display and the relevant node and controller flash Fig 11 22 State display example Color State Element Help text Red Pressed L...

Page 135: ...alse AAUTO AUTO output Green True Gray False ATEST TEST output Green True Gray False Res1 Reserved signal Green True Green False RAE2 Drives contactor auxiliary contact Gray True Gray Open E2 keyswitc...

Page 136: ...n error Node XX Hardware error Node XX Communication error Node XX Software error Node XX IO monitoring error Node XX Error protocol received Node XX Crossed connection error Node XX RAM error Node XX...

Page 137: ...figure softkey Description All the nodes present in the ESC circuit are determined when the ESC diag nosis is started The number of nodes and the order of the node types define the structure of the ES...

Page 138: ...ngs are overwritten Softkey Description Next Window The first node is highlighted Insert Rob A controller is added Delete Rob The selected controller is removed Move left The selected controller is mo...

Page 139: ...ed Fig 11 26 Example robot property boxes Parameter Description Name Name of the controller Shortcut Short designation of the controller Icon Controller icon Config name Name of the current configurat...

Page 140: ...t a signal The display of the signals can be activated or deactivated for the ESC diagnosis by pressing the space bar Fig 11 27 Configuring ESC nodes Softkey Description Next Window The first node is...

Page 141: ...boxes for by pressing the Property softkey The property boxes of the selected ESC node are displayed and the softkey changes to Show signals Description The four property boxes of the selected ESC no...

Page 142: ...of the ESC node list 11 13 14Error messages and troubleshooting Fig 11 29 Example KPS property boxes Parameter Description Name Name of the node Shortcut Short designation of the node Icon Node icon C...

Page 143: ...sor errors Communication error Defective KCP KPS or CI3 board EMC interference defective connectors or con necting cables Exchange the defective mod ule reduce the interference carry out a visual ins...

Page 144: ...A B inter changed Check wiring of the input for enabling switch 1 ZS1 Crossed connection error on Operating mode switch Short circuit TA24 A TA24 B Single channel wir ing Channels A B inter changed C...

Page 145: ...e Directive of the European Parliament and of the Council of 22 June 1998 on the approximation of the laws of the Member States relating to machinery 1998 EN 418 Safety of machinery EMERGENCY STOP equ...

Page 146: ...6 2 Generic standards Immunity for industrial environments 2002 EN 61000 6 4 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments 2002 EN 61800 3...

Page 147: ...e or modifications Archive of the software Application used Any external axes used Description of the problem duration and frequency of the fault 13 2 KUKA Customer Support Availability KUKA Customer...

Page 148: ...94 info kuka be www kuka be Brazil KUKA Roboter do Brasil Ltda Avenida Franz Liszt 80 Parque Novo Mundo Jd Guan CEP 02151 900 S o Paulo SP Brazil Tel 55 11 69844900 Fax 55 11 62017883 info kuka robote...

Page 149: ...many Tel 49 821 797 4000 Fax 49 821 797 1616 info kuka roboter de www kuka roboter de Hungary KUKA Robotics Hungaria Kft F t 140 2335 Taksony Hungary Tel 36 24 501609 Fax 36 24 477031 info kuka roboti...

Page 150: ...ong 47100 Puchong Selangor Malaysia Tel 60 3 8061 0613 or 0614 Fax 60 3 8061 7386 info kuka com my Mexico KUKA de Mexico S de R L de C V Rio San Joaquin 339 Local 5 Colonia Pensil Sur C P 11490 Mexico...

Page 151: ...373 3869 www jendamark co za Spain KUKA Sistemas de Automatizaci n S A Pol Industrial Torrent de la Pastera Carrer del Bages s n 08800 Vilanova i la Geltr Barcelona Spain Tel 34 93 814 2353 Fax 34 93...

Page 152: ...hailand Office c o Maccall System Co Ltd 49 9 10 Soi Kingkaew 30 Kingkaew Road Tt Rachatheva A Bangpli Samutprakarn 10540 Thailand Tel 66 2 7502737 Fax 66 2 6612355 atika ji net com www kuka roboter d...

Page 153: ...CI3 Tech board fuses 110 CI3 Tech board LEDs 111 CI3 Tech board relays 32 Circuits safety oriented 55 COM 1 serial interface 14 COM 2 serial interface 14 Connecting cables 11 Connecting cables connect...

Page 154: ...t controller 80 Interface X11 71 Interfaces 39 Interference voltages 38 Intermediate circuit 34 Internal fan exchange 90 Introduction 9 J Jog mode 57 59 K KCP 11 62 KCP connection 39 KCP connector X19...

Page 155: ...S1 40 Power supply unit KPS 600 33 Power supply units 32 Power unit 11 32 Pressure Equipment Directive 145 Pressure relief plug exchange 91 Processor 15 Product description 11 Programming 64 Propertie...

Page 156: ...73 Test output B 73 Top mounted cabinet 31 Training program 9 Transport position 63 Transportation 63 77 Transportation fork lift truck 78 Transportation lifting tackle 77 Troubleshooting 103 U Univer...

Page 157: ...157 157 V3 3 11 07 2007 KRC AD KRC2ed05 BA en...

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