KUKA C4 Drive KSP600-30X20 Explosion Fault Repair
The customer purchased a KUKA C4 drive KSP600-3x20 00-198-266 ECMBS3D2224BE531 from us, but on the first day of receiving it, the machine exploded. We have to ask the customer to send it back for repair.
After receiving the driver KSP600-3x20, we opened it and found that one of the SEMICON IGBT modules was burnt out. It seems that the power consumption was instantly too high, and the heat could not be dissipated, causing the internal temperature to be extremely high, producing gas that broke through the shell and caused an explosion.
Upon inquiry, the customer was informed that their original driver KSP600-3x20 also had an IGBT module burnt out. After replacing the newly purchased driver KSP600-3x20, the machine exploded and reported the following fault:
1. KSS26012 confirms general servo error (A6) error source: Drive
2. KSS26139 overcurrent (Servo) (A6) error source: Drive
3. KSS26230 charging thyristor short circuit (Supply) (1) error source: Drive
4. KSS26015 General power failure (1) Error source: Drive
5. KSS01008 controller cold start
6. KSS00106 performs zero point correction A6
7. KSS 15054 turns off space monitoring (adjustment error)
8. Error occurred during KSS01421/R1/z21:1 analysis
After the customer restarted, there were only 4 error messages left:
1. KSS26230 charging thyristor short circuit (Supply) (1) error source: Drive
2. KSS26015 General power failure (1) Error source: Drive
3. KSS00106 performs zero point correction A6
4. KSS 15054 turns off space monitoring (adjustment error)
From this, it can be inferred that at the moment of power on operation, two serious errors occurred, namely "KSS26139 overcurrent" and "KSS26012 confirming general servo error", followed by the following four warnings and two reminders. Then, based on the IGBT module explosion, it can be determined that "KSS26139 overcurrent" is the root cause.
But the driver KSP600-3x20 we sell to our customers has been tested before shipment and is in good condition, so the initial cause of the problem is not the driver. Upon re examining the four warnings after the restart, it was found that the "KSS26230 charging thyristor short circuit" was most closely related to the burning out of the IGBT module. So after carefully examining its detailed description, we found that the motor cable was the most likely cause, and the two serious errors, KSS26139 overcurrent and KSS26012 confirmation of general servo error, both mentioned six axes. Therefore, we asked the customer to investigate the cables, with the six axis motor cable being the focus.
After the customer's investigation, they indeed found a broken electrical cable. We sent the repaired driver KSP600-3x20 to the customer. After replacing the damaged cable, the customer installed the driver KSP600-3x20 and tried it out. This time, the machine did not explode. Then the customer did some debugging themselves and resumed production.
