KRC2 blank screen on startup

    Hi everyone,

    I’m working on a Kuka KRC2 and have been having quite a few issues with it.

    Upon startup everything powers on except for the pc, I am only able to get it to start by jumping the pins on the motherboard

    The model of the motherboard is: SY-7VBA133K


    After it starts up, the teach pendent does not power on, I’ve also attached a monitor to the VGA card but I just get a black screen


    Here is what I have done so far to try and fix this

    1- replaced the CMOS batter with a NEW one, checked voltage before installing

    2-Sprayed all connections and ports with contact cleaner, left to dry before power on to be safe

    3-Checked voltage on PSU and all were within spec

    4-Swapped ram with spare from working robot, still no luck

    5-Swapped KCP-VGA card with working robot, still no output to monitor

    6- Visually checked all capacitors, none look like swelled

    7- checked all fuses

    Unfortunately after doing all of this I haven’t gotten anywhere, in the past I fixed this by just replacing the motherboard from a spare machine but they are quite expensive so I’m just trying to rule everything out.

  • Fubini June 12, 2024 at 3:37 AM

    Approved the thread.

    at some point CMOS battery was toast so CMOS memory was lost... or...

    if battery was replaced before it was completely gone, replacement process took too long (more than 30sec or so). this means that backup capacitor run out of juice and CMOS memory was still lost.

    the solution is to go back into the BIOS during powerup and load KUKA default settings. among them is also setting that dictates behavior on power on. this allows KPC to boot when power is present (otherwise it waits for button press, which is what you jumped to get it to start).

    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

    external monitor is only needed on newer systems that use smartPad.

    but this is a KRC2 with non-intelligent teach pendant.

    this means BIOS output is shown during boot process so you do not need an external display - just look at the display of the teach pendant. everything you see before message "starting windows" is BIOS output. for example, something like this. and note message to enter BIOS. in this example you need to press F2 to get in and make changes. On most motherboards this is usually an F1, F2, F10 etc. so yeah... you need keyboard since teach pendant does not have function keys.

    33347-whatsapp-image-2022-02-18-at-12-52-14-jpg

    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

    The display of the external monitor will be shown after windows has started (and there is no way around).

    Windows95 and KSS V4 or earlier:
    sm.com (autoexec.bat or directly called)

    WindowsXP and KSS V5 or V7:
    KUKA.VGA driver will be set for showing on external Monitor (as well).

    Showing BIOS on bootup requires a VGA card (replacing the KUKA.VGA card)

    Kuka VGA is working (tested it on other robot) but even after jumping power pins to turn the pc on there is still no output to both the monitor or teach pendant. This whole system was working just a few days ago which is really confusing to me since the only thing that has changed was replacing the CMOS battery, so I should be getting something. My external mouse is getting power when it boots up, I also see a light turn on, on the DSE-IBS board on startup

    well... did you follow ESD guidelines? if not, getting inside KPC is enough to damage something. and KVGA is one of more sensitive things. i would not be too surprised if it is dead now. replacing CMOS battery should be pretty safee but removing KVGA, plugging it into another PC and removing it again and plugging it back screams for attention... if you are lucky, maybe KVGA just need to be reseated...

    but it could be other things too. for example KCP backlight may have failed. or shoring pins on the header may have lead to damage.

    since you have another robot, try just swapping pendant to see if that part is ok. then you may try testing KVGA but... be careful.. you may introduce more problems if not doing it right.

    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

    Esd guidelines were followed to a degree, I was grounded to the controller the entire time I was working on it, removed parts were placed on a non ESD safe mat however…

    I managed to get an output to a monitor after replacing the KVGA and cleaning motherboard with contact cleaner, I guess I must’ve killed it:/ Still no output on the teach pendent unfortunately but I have run into a new problem though, after startup I seem to get stuck at the KUKA-Cross-3 screen, I have tried reseating the ram although it did not solve the problem, I saw many other posts with issue so I will go through those and see if I can solve it.

    Thank you for all the help.

    that is another thing... HDDs are items that move alot... they are subject to wear... and the older the system the more important it is to have a replacement with cloned image. this allows for quick recovery in case of failure/corruption as well as confirming if in case of problem it is the software or hardware issue.

    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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