11/06/2016 Contact problem or incorrect plug connection on the CCU ­ Xpert@work

Andrei Florea, florea 2016‐06‐11

© KUKA Roboter GmbH 2016 ‐ Xpert@work content is only for KUKA internal use!

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Cause English

Contact problem or incorrect plug connec⁸潂on on the

CCU

Check ⁸潂me Fast

Descrip⁸潂on

© KUKA Roboter GmbH 2016 ‐ Xpert@work content is only for KUKA internal use!
Andrei Florea, florea 2016‐06‐11
Contact problem or incorrectly connected plug connec⁸潂on on the CCU, e.g. X1, X3,
X4, X31.

Connec⁸潂ons

Connec⁸潂ons on the CCU

Item Con‐ Descrip⁸潂on

http://xpert.roboter.kuka.de/#/detail/2072350f­3915­4132­a655­4a517e91a7ed?print=true&tid=3f76c7d8­5414­4f60­9524­286f1f1f3dff 1/4
11/06/2016 Contact problem or incorrect plug connection on the CCU ­ Xpert@work
Item Con‐ Descrip⁸潂on
nector

1 X14 External fan connec⁸潂on

2 X308 External power supply, safety circuit

3 X1700 Board connec⁸潂on

4 X306 smartPAD power supply

5 X302 SIB power supply

6 X3 KPP1 power supply

7 X29 EDS connec⁸潂on, memory card

8 X30 Ballast resistor temperature monitoring

9 X309 Main contactor 1 (HSn, HSRn)

© KUKA Roboter GmbH 2016 ‐ Xpert@work content is only for KUKA internal use!
Andrei Florea, florea 2016‐06‐11
10 X312 Main contactor 2 (HSn, HSRn)

11 X310 Spare (safe input 2/3, safe output 2/3)

12 X48 Safety Interface Board SIB (orange)

13 X31 Controller bus, KPC (blue)

14 X32 Controller bus, KPP (white)

15 X311 Safe inputs, ZSE1, ZSE2; NHS (jumper plug)

16 X28 Mastering test

17 X43 KUKA Service Interface (KSI) (green)

18 X42 KUKA Operator Panel Interface smartPAD (yellow)

19 X41 KUKA System Bus, KPC (red)

20 X44 EtherCAT Interface (KUKA Extension Bus) (red)

21 X47 Spare (yellow)

22 X46 KUKA System Bus, RoboTeam (green)

23 X45 KUKA System Bus, RoboTeam (orange)

24 X34 Controller bus, RDC (blue)

25 X33 Controller bus, spare (white)

26 X25 Fast Measurement inputs 7 ... 8

27 X23 Fast Measurement inputs 1 ... 6

28 X11 Alarm contact for main switch

29 X26 Thermosta⁸潂c switch for transformer

http://xpert.roboter.kuka.de/#/detail/2072350f­3915­4132­a655­4a517e91a7ed?print=true&tid=3f76c7d8­5414­4f60­9524­286f1f1f3dff 2/4
11/06/2016 Contact problem or incorrect plug connection on the CCU ­ Xpert@work
29 X26 Thermosta⁸潂c switch for transformer

30 X27 Alarm contact for cooling unit

31 X5 KPP2 power supply

32 X22 Op⁸潂ons power supply

33 X4 KPC, KPP, internal fan power supply

34 X307 CSP power supply

35 X12 USB

36 X15 Internal cabinet fan (op⁸潂onal)

37 X1 Infeed from low‐voltage power supply

38 X301 24 V without ba͇ery backup (F301)

39 X6 24 V without ba͇ery backup (F6)

© KUKA Roboter GmbH 2016 ‐ Xpert@work content is only for KUKA internal use!
Andrei Florea, florea 2016‐06‐11
40 X305 Ba͇ery

41 X21 RDC power supply

The procedure for checking whether the plug connec⁸潂on is defec⁸潂ve is as follows:

Inspec⁸潂on instruc⁸潂ons
1. Check whether the connectors are correctly connected. Par⁸潂cular a͇en⁸潂on
must be paid to:

Pins pushed in

Corrosion

Scorched contacts

Connector insert pushed back

Connector on correct slot

2. Check whether the cable is mechanically damaged. Causes of squashed

cables or wires can include the following:

Cable straps too ⁸潂ght

Clips too ⁸潂ght

Trapped when closing a cover

Bend radius too ⁸潂ght

3. Check whether the cable s⁸潂ll conducts electricity. Par⁸潂cular a͇en⁸潂on must
be paid to:
http://xpert.roboter.kuka.de/#/detail/2072350f­3915­4132­a655­4a517e91a7ed?print=true&tid=3f76c7d8­5414­4f60­9524­286f1f1f3dff 3/4
11/06/2016 Contact problem or incorrect plug connection on the CCU ­ Xpert@work

Cross‐connec⁸潂on of individual wires

Short‐circuit of individual wires with the ground conductor

Correct wiring in accordance with circuit diagram

 Message (5)

KSS15016
Ackn.: Stop due to stands⁸潂ll monitoring viola⁸潂on
CrossMeld 15016
Ackn.: Stop due to stands⁸潂ll monitoring viola⁸潂on
CrossMeld 12005
Ballast resistor temperature sensor: open circuit

© KUKA Roboter GmbH 2016 ‐ Xpert@work content is only for KUKA internal use!
Andrei Florea, florea 2016‐06‐11
KSS12005
Ballast resistor temperature sensor: open circuit
KSS26205
Ini⁸潂aliza⁸潂on failed ({Device number}) {Device type}

 Solu⁸潂on (1)

Andrei Florea, florea 2016‐06‐11

© KUKA Roboter GmbH 2016 ‐ Xpert@work content is only for KUKA internal use!

http://xpert.roboter.kuka.de/#/detail/2072350f­3915­4132­a655­4a517e91a7ed?print=true&tid=3f76c7d8­5414­4f60­9524­286f1f1f3dff 4/4