KUKA KRC2 Servo Error

    Hello forum members,

    I'm new among you,


    We have 2 krc2 same model robots, one of these robots was constantly giving a master error in the past weeks. After processing 5-10 products, there was a loss of master and it was giving an error. While operating the robot 3 days ago, this time the main fuse turned off. Later, when we wanted to open the fuse and run it again, one of the KSD1-32 model drivers burned out and the device was turned off immediately.


    When we removed the driver, we saw that the processor part was burned and the driver was not working at all. We found a used and working KSD1-32 drive and replaced it. When we turn on the robot, the green and red leds of all drivers flash continuously and when the device is turned on, it gives the warnings in the pictures.


    We tried our KPS600 device on our other robot and it worked. Again, we took all the bus cables from our other robot and plugged them into our defective robot, but nothing changed, we changed the DSE card and still no change.


    Did anything happen that we should check out or something like that?

    Can you help us?

    thanks.

    please read pinned topic READ FIRST.

    you should post ALL messages. and read them. they suggest that some of the drives are not connected, or are not connected correctly. check the connection, cables and if all units are really supplied. each drive gets two supplies, high voltage (thick black wires) and low voltage (blue wires).

    if one of the drives got damaged, it may have affected other units it is connected to. usually this would be fuses or maybe supply wiring but ... it could be more than that. a well placed disturbance or transient can knock out bunch of nodes. so you may have to broaden your search.

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

    Hello, first of all, thank you.


    I checked the connection cables, we have a second robot working the same model, I tried it with the cables on the working robot, but still nothing changed. As for voltage, the Blue wires show 27 volts but I don't quite understand how many volts I should get on the black wires. Is it AC? Is it DC? And how many volts does it need to be?


    There is no voltage in the black wires when measured as AC,

    it shows 1 volt when measured with DC.


    The values I measured when this robot was first turned on gave the same values in the other working robot, so there was no indication of voltage. I checked the fuses, there are no closed fuses or defective fuses. As I said, when I attach the KPS600 module to the other robot, it works without any problems. There is a place that I missed, but I couldn't find where exactly. Thank you.

    Transcribing error messages properly instead of using blurry screenshots is polite. Also, there appears to be a scroll bar at the right end of the message window, implying there are more messages not shown in that photo.


    The "DSE Participants" message suggests that the Interbus communications between the KSP and the first KSP is broken. The Interbus uses white cables that look like ethernet RJ45 cables, and daisy-chains from DSE>KSP>KSD1>KSD2>KSD3... and so on.


    DSE Participant 1 should be the KSP, 2 should be KSP1, etc. So the DSE and KSP are probably correct. Check all the Interbus cables.


    Which axis KSD did you replace?

    Quote from fx2006

    the Blue wires show 27 volts but I don't quite understand how many volts I should get on the black wires. Is it AC? Is it DC? And how many volts does it need to be?

    you should read schematics. black wires connecting to drives X1.1 and X1,2 are high voltage DC bus.

    when system is faulted, this bus drops but in operation it goes to several hundred volts.

    but you mention to have two robots and that means you can compare values.

    Quote from fx2006

    there are no closed fuses or defective fuses.

    not sure what you mean by closed fuse. normal state of fuse is low resistance.

    Quote from fx2006

    when I attach the KPS600 module to the other robot, it works without any problems. There is a place that I missed, but I couldn't find where exactly. Thank you.

    That is one component. KRC2 has bunch of other things in there. Messages you have suggest that problem is related to INTERBUS. as mentioned check the connections and post all messages. check schematics. bus connections go from one unit to the next. if one connection is interrupted, rest of the chain will not be seen. it looks like you failed to connect it to A1 drive (marked with "N1" on a little yellow sticker next to it).


    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

    Hello again, first of all thanks for your help.


    At the moment, I only have the authority to upload 1 image to the form, so it is difficult for me to give detailed information.


    the second drive from the bottom left, which failed and did not have a yellow label on the drive we replaced


    I tested by replacing all DriverBus cables, I changed the cable on each driver but nothing changed. All fault records that appear on the screen when the device is first turned on are as follows;


    Time No Source Message

    00:19 1008 Controller booted

    00:20 55 Initialization of the DSE

    00:20 223 Power module axis A1 not or wrongly plugged

    00:20 223 Power module axis A2 not or wrongly plugged

    00:20 223 Power module axis A3 not or wrongly plugged

    00:20 223 Power module axis A4 not or wrongly plugged

    00:20 223 Power module axis A5 not or wrongly plugged

    00:20 223 Power module axis A6 not or wrongly plugged

    00:20 28 Drivebus DSE 1 participant No 2 - 7 does not exist

    00:20 26 MODULE A1 KSD-32 REQUIRED

    00:20 26 MODULE A2 KSD-32 REQUIRED

    00:20 26 MODULE A3 KSD-32 REQUIRED

    00:20 26 MODULE A4 KSD-32 REQUIRED

    00:20 26 MODULE A5 KSD-32 REQUIRED

    00:20 26 MODULE A6 KSD-32 REQUIRED

    00:20 200 KS Drives Contactor off

    00:21 0 TPUSER Initialization in progress

    00:21 0 TPUSER Initialization finished

    00:21 40 BOF PowerOn finished


    We tried the KPS600 on our other robot, the same model, which worked as I mentioned before, and it worked without any problems, we also changed the DSE card installed in the computer, there was no change again, there is no faulty or non-working fuse, I checked all the fuses, I looked at the contactors, they are all active, a few more photos for you. I'm sending it, if you can help me check the following part, I would appreciate it again. Thank you.

    You need to test other elements in the chain. Follow the bus chain...

    1. MFC+DSE

    2. Cable1

    3. KPS600

    4. Cable2

    5. KSD N1

    6. Cable3

    7. KSD N2

    8. Cable4

    9. KSD N3

    ...


    Its a chain... When one link is broken, end of chain is not connected. You need to find where the broken link is.

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

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