Author Topic: KRC4 Compact General power supply error  (Read 443 times)

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Offline dangermrrobinson

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KRC4 Compact General power supply error
« on: April 15, 2018, 02:47:51 PM »
Hello everyone!

I’ve been pretty stumped about what’s happening with our controller and manipulator. Controller is a KRC4 Compact and manipulator is KR10 R1100. Everything was working great until one day it threw error codes and did an override shutdown. Here are the error codes:

KSS26233 - Error: Intermediate circuit overcurrent (supply)(1) originator: drive
KSS26130 - Error: charging of intermediate circuit failed (supply)(1) originator: drive
KSS26015 - General power supply error (1) originator: drive

I did toggle the drives on/off and even did a cold start to clear off codes. Error codes only appear when I press the enabling switch. All signs point out to a KPP problem. When I looked inside the KRC4 compact, no error faults nor fuses were blown. And when I did a visual inspection in the drive box, I didn’t see any signs of burnt cables or liquids dripping. Usually with high voltage electronics, there should be some sort of sign pointing out to a problem with either LED faults and/or burnt cables/capacitors/boards.

Still pretty new to the Kuka world. Any advice would help. Thank you very much for your time.

Offline SkyeFire

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Re: KRC4 Compact General power supply error
« Reply #1 on: April 16, 2018, 01:29:01 PM »
Given their reliability requirements, the KPP modules are designed to (ideally) fail before they hit the point of producing arcs, sparks, or obvious carbon scoring.

This doesn't always work, in conditions where people leave the cabinets open and allow dust, oil vapor, or other contaminants to accumulate inside the modules, but that doesn't appear to be the case here.

If you have another KRC, or a stock of spare parts, the quick option is probably to try swapping out the KPP and see what happens.

Offline dangermrrobinson

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Re: KRC4 Compact General power supply error
« Reply #2 on: April 16, 2018, 02:43:42 PM »
Ordering the spare part from Kuka. Hopefully an engineer comes and gives advice of preventing this happening again. The unit is barely a year old. If you or the rest of the community have any suggestions, please chime in. Our power is rated at 220, single phase. Our robot is used for film and entertainment, hence traveling from studio to studio. Besides a dedicated circuit, what box in between the controller and mains should we purchase to further protect our investment?

Offline SkyeFire

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Re: KRC4 Compact General power supply error
« Reply #3 on: April 16, 2018, 04:13:35 PM »
Hm.  Well, I would ask KUKA about the possibility of getting a root failure analysis done on the bad unit.  It could just be a case of a lemon getting past quality control.

Beyond that, if you think local power conditions are to blame, I would suggest looking into a mains power conditioner, or possibly a high-end UPS (with sufficient output to support the robot's max current draw), to clean up harmonics or other "dirty" factors in the power supply.

Offline dangermrrobinson

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Re: KRC4 Compact General power supply error
« Reply #4 on: April 16, 2018, 09:09:20 PM »
thank you very much again! I'll keep the community updated with the outcome.

Offline dangermrrobinson

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Re: KRC4 Compact General power supply error
« Reply #5 on: April 20, 2018, 01:28:35 PM »
Thank you very much @SkyeFire and the rest of the community. I’ve learned a lot from reading this forum. Just to let everyone know that our KRC4 Power problem was rectified. It was indeed just a bad KPP board.

However, it’s still not a bad idea to protect your investment. If anyone can suggest a high end UPS that has been tested, or even an isolation transformer, that will be great. I know Kuka sells an isolation transformer unit but only for their bigger cabinet. Looking for a solution using a KRC4 Compact.

Thank you!