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KUKA Robot Controller
Power Supply · Intermediate
KUKA Robot KRC0046 - OVERVOLTAGE <power module number>
The intermediate circuit voltage in the power module has exceeded safe operating limits, indicating a critical power delivery issue. This condition requires immediate investigation of the power supply chain and energy dissipation systems to prevent damage to drive electronics and potential system failure.
KRC0046
KUKA Robot KRC0046 - OVERVOLTAGE <power module number>
OVERVOLTAGE <power module number>
The intermediate circuit voltage in the power module has exceeded safe operating limits, indicating a critical power delivery issue. This condition requires immediate investigation of the power supply chain and energy dissipation systems to prevent damage to drive electronics and potential system failure.
Common Causes
- Defective or failed ballast feedback resistor preventing proper voltage regulation
- Open or blown ballast fuse in the power module circuit
- Malfunctioning power module with internal voltage regulation failure
- Brake ramp deceleration profile set too steep causing regenerative energy surge
- External power supply delivering voltage above nominal specifications to the robot controller
Troubleshooting Steps
- 1Check the input AC power supply voltage at the main contactor terminals to confirm it matches specification on the KRC4 cabinet nameplate
- 2Visually inspect the ballast fuse in the power module for discoloration, damage, or blown condition and replace if necessary
- 3Measure resistance of the ballast feedback resistor using a multimeter and compare against machine data specifications in WorkVisual
- 4Review and adjust brake ramp deceleration parameters in the axis-specific machine data to reduce steepness of descent profiles
- 5Use the KUKA smartPAD diagnostics menu to monitor real-time intermediate circuit voltage and verify stability under idle and motion conditions
- 6If voltage remains elevated after parameter adjustment, contact KUKA service as the power module may require replacement
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