KSU sending worrisome messages

If you already changed 2 KSP, would be good to start looking that robot is not overloaded or at least check load_data. Possible causes for this message are in the attachment either load is to great for the robot used, or you can try to adapt program velocity(maybe this issue is occuring always at the same positions) and you already changed 2 KSP. Also check if your WV configuration matches the real KSP's. I also had an issue where KSP in WV was for 64A but inside the cabinet it was KSP 40A. And the controller didn't complain at all. But parameters for drive were higher with 64A than for KSP40A by comparing the .xml configuration files.

Ok, then robot isn't overloaded, but you already exchanged two KSP(I hope they were changed with the same type), so the problem shouldn't be in the KSP then. Are these only messages that robot displays? You could also inspect the connections (connectors, poor connection) going from motors to cabinet and inside cabinet from X20 to KSP or even connections between KSP's and KPP. You could try with KPP, but I guess then you would have general servo errors for all axes, not just for the wrist.

You have your KSP's in the project structure windows when you download or open the project.

For general servo errors possible causes also in the attachment. So doing cold boot second time resolves the issue. You could try the procedure with Reload files as in the attachment. Is your robot set to hibernate or coldboot?

If the drives are blowing up i would definitely measure input voltage (both phase to phase and phase to ground, that is 6 measurements). and make sure that KRC is using settings and catalog elements that match supply voltage. Also check ballast resistors... If not connected or wrong type or damaged, they will not be able to their job and intermediate voltage will get higher when decelerating or stoping robot.... Because in such case motors work as generators and put energy back into DC bus (intermediate circuit). Also make sure load values are correct.

Quote from Wall-E

The tool weight is 40kg ; that should be fine for a KR210.

what proof you have for that? Load is not just mass ..

you stated before that messages show up when you try to move robot:

Quote from Wall-E

As soon as I move the robot in T1, some scary warning about "general servo error" or "Intermediate circuit voltage too high" pops up.

Quote from Wall-E

How can I check the ballast resistors ? Are they inside the KSP ?

I'd hate to open these babies...

Ballast resistors are located in the back of the controller, inside of the controller they are marked with R1 in R2. They each have 22ohms and they are connected in parallel. Also i would try with reload files, if you still didn't tried it.

Because errors come and go, so there is no option but to check and rule things out one by one, like panic mode advised, and really check things by measuring etc. and for example one could have 40kg mounted on the KR210 but those 40kg could be mounted also 5m away, not directly on the flange, also one could have 40kg mounted on the flange and $LOAD values way off (for example for M 230 kilos entered, center of gravity way off, inertia) and the robot would tried to work with those values regardless if there is only 40kg mounted.

what is the EXACT version of KSS? There are few dozens of releases... early releases are obviously more prone to bugs - that is why later releases exist. if this is an older variant of 8.3 I would look into upgrading KSS to something more recent. if you have usb recovery stick and know how to use it, you could do it yourself, license and tech options are same as long you are within 8.3 family.

but if the drives have been replaced more than once, i would have a good look at power grid and anything related.

so far several suggestions were made - check voltage, check load, check ballast resistors etc. but nothing came out ...

the mains is spot on and symmetrical which is good.

in comparison, here i have dealt with couple of plants with considerably higher voltage (627-629V phase to phase instead of expected 575V). that is already nearly 10% over the expected so it does not take much of a disturbance to take it out of spec.

the picture of tool has nothing to scale and robot is folded so one cannot even tell if it is mounted correctly.

and how exactly do you plan to use it?

well... pardon my French... but... how exactly are you planing to use it...?

did you think this through? did you read the datasheet?

because that unit is not an isolation transformer. it is an auto-transformer. input and output side operate at different voltages. pretty sure France like rest of the continental Europe uses 400VAC phase to phase... and European KRC controlling KR210 is also meant to work on three phase 400VAC.

if you wire the transformer in a step down configuration, you can connect mains to 400VAC side and you will get lower voltage (240VAC or whatever) on the output.

if you wire it in a step up configuration, you cannot feed it from 400VAC mains - that is too high for 240V side of the transformer. and even if you did do that, output voltage would be 666V which is too high even for KRCs meant for North America.

or... do you plan on using two of those transformers connected back to back?

btw. from what i know, KUKA controllers come in 8kVA and 13kVA. anything over KR60 is fitted with 13kVA. but transformers that KUKA uses are "optimized" to be on the light side. which is why they have temperature switch embedded into transformer windings and this switch is monitored by the controller.

External transformers do not have that. so common practice when using external transformers is to pick something larger. you may want to check with your electrician on selecting proper unit that meets your electrical code.