RDC (and other) Errors with R900 Sixx and KRC4 SmallSize

I have recently purchased a used KR6 R900 Sixx with a KRC4 smallsize CCU. The control cabinet seems to be working fine, I was able to make backups and get WorkVisual connected, but so far I have been unable to get a connection to the robot. I've checked the X20/X30 and X21/X31 cables, and every wire has continuity between its respective pins so I don't think the cable is broken.

Inside WorkVisual I've downloaded the project from the cabinet and there is a second _Tray controller that is greyed out. I cannot seem to remove it in any way, I'm wondering if this is causing some of my problems and if there is a way to change the configuration for the cell to remove it? The company I purchased it from were using it as a parts loader I believe, and I guess it was interfacing with some other controller.

I have attached the error messages I see, I imagine KSS00272 (No robot number programmed) and KSS00276 (Machine data do not match robot type) might be the most relevant and might be causing the other issues? I also assume the Ethercat issues are a result of the _Tray controller not being available.

I tried setting $robtrafo[] value to $trafoname[] to try and fix the machine data not matching robot error but it didn't appear to do anything.

Here are the pictures of the logs, the WorkVisual project, and any other screens/images I figured might be useful

If anyone can point me in the right direction as to getting the robot arm itself to function correctly, I'd appreciate it.

Quote from Fubini

Robot serial number zero is typical if controller can not read data from rdc. So you should check in direction of rdc. Could be wiring or a defective rdc or eprom on rdc in my opinion. Is eprom plugged in correct on rdc? Serial number and other data is stored in there.

Thanks, I will check RDC. Based on this thread, I guess I also need to check EDS? I am having a lot of the same errors

Post

RE: KUKA KRC4 RDC Memory is Empty After Power Cycle

you attached same image twice. oldest messages are still not shown. you need to scroll down.

robot-forum.com/attachment/34506/

in KRC4 architecture, RDC flash is not on the RDC itself. it is on a separate unit called EDS that pugs into RDC. Check if the EDS is connected. if it is or if the ribbon cable is damaged, your robot will need new EDS. in fact there are two of them:

first one is connected to RDC and keeps track of robot data.

the second one is inside KRC4 and connected to CCU. this one is…

panic mode

June 6, 2022 at 5:23 PM

Am I correct in assuming I can find these beneath this IO cover on the robot arm itself?

Edit: I just confirmed with the Xpert portal R900 diagram, that is where they are. I will check them, as well as double check the X31 cable

So I think they just gave me the wrong data cable. Looks like it should be a 00-209-930 not a 00-174-774. I completely missed that. Guess I should have checked this stuff better before buying it (oops). Hope using the wrong cable didn't mess anything up. I was wondering if I could just move the pins but I'm missing 2 pins entirely. Not sure how I didn't notice. Here's to hoping it works when I get the right cable.

This is the correct pinout

And this is my cable

and this is the robot's connector

I received the new cable and after a lot of tinkering was able to get the robot to move in T1 Startup mode! I'm mostly just getting safety stop warnings now if not in Startup mode so I believe what I need to do next is fashion a DB50 connector with jumpers for X11 to close the safety stop pins. It's also complaining about the batteries which are dead but I've got replacements on order.

I can't seem to find the exact wiring diagram / pin out for my specific cabinet's parallel safety X11 (KRC4 small size), they all seem to be for a much larger connector, not the parallel safety connector X11 I have on the front lower left of my cabinet

I did find this but these seem to conflict with other diagrams I've been finding, and none of these 3 seem to apply to the KRC4 small size? Or maybe I'm just not reading this right, but I definitely don't have more than 50 pins which makes me think it's the larger X11 connector. Or does the KRC4 small size use the same pinout as the compact CCU?

Edit: I found some information in Xpert Portal, looks like KRC4 small size uses same pinout as Compact

I've been looking on the Xpert Portal but other than some random pin lists in different PDFs I haven't been able to find a good source of wiring diagrams for all the various connectors yet, but maybe I'm just blind.

If anyone can link the wiring schematic for the X11 parallel safety interface so I can jump the estop/safety stop/enable/operator safety etc pins, I'd greatly appreciate it! I'll continue searching for it on Kuka's website

Edit: I couldn't find full schematics but I did find pieces of the different pinouts in the Assembly Instructions pdf which was enough to confirm it uses the same pinout as Compact. I don't know how I missed this before

I will try using the Compact schematic for my X11 connector and see how it goes.