KRC2sr Controller

[gouch]

Hello,

Has anybody come across issues with certain alarms that occur on a krc2-sr controller where the controller has to be powered down and up again to reset the faults. I think  the errors are due to overcurrent on one of the axis or similar faults that may occur if a part gets jammed or something similar.

I know the krc2-sr only does a cold start and thats why it takes so long for the controller to reboot, but is it normal/correct to have to reboot a controller to clear an error where a torque/current setpoint is exceeded for an axis.

[SkyeFire]

What's a KRC2-SR?

What version of KSS is it running?

What is the EXACT error message and number?

In general, though, no, it should never be necessary to power-cycle the controller to clear a fault, unless one of the OS modules has crashed, which should be an EXTREMELY rare event.  Overtorque and collision errors definitely do not cause this behavior under any normal circumstances.

[optimus_prime]

KRC2-SR stands for Small Robot - SCARA/SIXX types below KR-3 robot.

Its not recommended to shut off after overcurrent/over torque fault. Just jog in 1% override & try to move out the robot of the fault position.
If all options go waste then go in FOR COLD START...

[gouch]

Sorry for not getting back sooner, have been out of the office.

The version is V7.0.10.

When a crash occurs, the following messages come up;

Entry 5171 (System, Warning)
Internal Controller Error 0x0303914b (File: SRDLibInterface.cpp, Line: 55)
Module: System   MsgNo: 31003

Entry 5170 (System, Error)
Dynamic braking active
Module: System   MsgNo: 108

Entry 5169 (System, Error)
Drives contactor off
Module: System   MsgNo: 200

Entry 5168 (System, Warning)
Stopped A3
Module: System   MsgNo: 1100

Entry 5167 (System, Error)
Dynamic braking active
Module: System   MsgNo: 108

Entry 5166 (System, Warning)
Positioning monitor A3
Module: System   MsgNo: 1105


I think that the restart procedure in place for the operators was not fully correct. The alarm messages were only acknowledged once and when the drives were restarted (Automatic Mode is used), the active commands inhibited message was displayed and the operators were not going back to acknowledge the new messages. They then powered down the robot.

It has been recommended to upgrade th firmware to The version is V7.0.14. Can anybody tell me what is involved in this, is it a 5 minute job or a 2 hour job. Downtime will be an issue.I have the cd with the upgrade. Is there a manual with the steps to follow for the upgrade. Are there any pitfalls that can arise during this upgrade or is it straight forward?

Thanks for your responces.

[gianne]

Last year i used a krsixxx with krc2-sr controller, and it didn't make a cold start every time, there was windows hibernating; probably you have someting set in windows register.

gianne

[SkyeFire]

Well, most of those errors aren't too serious.  The "Dynamic Braking" error is a result of the A3 and/or Internal error.  "Drives Contactor Off" is just a status message that the drives are, well, off.

The A3 errors suggest that Axis 3 is physically jammed against something.  Usually these errors pop up when someone jogs the robot into an obstruction.  However, I take it this is not the case?

The Internal Controller Error is the one that worries me.  I have no experience with the SR controllers, so I can only extrapolate from my experience with KRC1s and KRC2s.  Usually a message like that in a KRC2 means that you have to re-install KSS.  More rarely, it can indicate a RAM or Motherboard or Hard Drive issue.

As for the KSS upgrade, there should be a manual on the CD (search for PDF files).  If it works the same as installs on KRC2s, it should take less than an hour.  You'll probably spend more time putting all your programs and settings back into the robot.

[gouch]

The cd is onsite where the upgrade is to take place. I do not physically have it. Would you have any pdfs from the krc2 upgrade as I will be only onsite the day the upgrade is to take place and I want to plan everything I can to avoid the dreaded downtime.

There is only a single program file running so that wont take long to copy over. What settings will be affected, remastering, reteaching points etc.


Would you advise to reinstall the KSS. I dont think that there ever was a resetting error, just a lack of understanding on the operators part about the reset procedure.

[gouch]

I installed the software upgrade to V7.0.14. The error Internal Controller Error 0x0303914b (File: SRDLibInterface.cpp, Line: 55) no longer appeared and was replaced with positioning error axis 3. I did not have to change any settings or do any reteaching of points.

[SkyeFire]

Well, that's good news, if not great.  It looks like you have cleared up the Internal Controller Error, but still have a hardware-level issue with Axis 3.  This could be several things:

Loose wire causing the brakes on A3 not to release reliably.
A bad servo cable. 
Something going inside the servo -- for example, the resolver might not be firmly fixed to the drive shaft anymore.
Servo amp for A3 going bad.

On a regular KUKA robot, this is where I'd start swapping parts around, but I don't know how possible that is on this model.  In a regular KRC2, you can usually swap servo amps between motors without any issues, as long as the amps are the same model -- that's a quick way of testing if the problem is in the amp. 
I'd also try feeling the motors while closing and opening the brakes, and see if the A3 motor feels any different from the rest.  You should generally be able to feel the brakes opening.  Also, if you can get A3 to jog at all, see if it makes any odd noises.
If the A3 motor is the same model as one of the other motors on the robot, my usual course of action is to swap the motors and see if the problem moves with the motor.
If swapping the servo amp and the motor doesn't move the problem from A3 to another axis, then it's most likely that the culprit is a bad A3 servo cable.