I should start by saying that the CCU board on this controller was replaced by a KUKA technician back in late April of this year. The OLD CCU board was not necessarily faulty that I know of but was replaced anyways to rule it out.
Upon arriving this morning 9AM CST, the SmartPAD was displaying the message “connection to controller is invalid”
I connected a monitor to the controller and all the error messages (attached) are displayed indicating a loss of connection to the following:
- RDC (Resolver Digital Converter) (this was an acknowledgement message not shown in the attachment unfortunately >>> “RDC 31: No connection to RDC possible”)
- X21 and X31 connectors look fine
- Connectors on the RDC board itself at the base of the robot seem to be well-crimped
- KCB (Kuka Controller Bus)
- No data cable LED activity on the KPC-side
- X31 reseated
- KSB (Kuka System Bus)
- No data cable LED activity on the KPC-side
- X41 reseated
I also find that I’m unable to activate the safety configuration, so there’s an invalid connection to the SIB. All of this tells me that CCU board is at fault.
No blown fuses. There is LED activity on the raised CCU pcb, but NO LED activity on the large pcb underneath.
The CCU power supply X1 connector pins correctly read 27V and seem well crimped. External power supply X308 is jumpered.
Removing data cables does not cause any additional errors to be displayed.
The Logbook shows a “Mains power failure” today at 7:30AM. Nobody has cycled power to the machine or the KRC before I arrived that I’m aware of.
