KEBA KeControl series controllers

KEBA KeControl series controllers

Product Overview

The KeControl series is a full scenario controller solution launched by KEBA for industrial automation, based on the Linux FlexCore unified software platform, achieving consistent development experience and functional reuse across hardware. The product is designed with the core concept of "real-time performance, scalability, and scene adaptability", covering three major forms: compact modular (C5), centralized high I/O (C1), and driver integrated (D3). It is equipped with Intel's full range of processors, integrated with FPGA hardware level EtherCAT master station (cycle time 62.5 µ s, data jitter<100ns), supports high-performance algorithms such as Fast Reaction Control, and can reduce control loop dead time by 66%, steady-state time by 46%, and overshoot by 6 times.

The product is widely compatible with applications such as injection molding machines, robots, automated production lines, extruders, etc. It has passed CE (2014/30/EU, 2011/65/EU), UL 61010-1/201 certification, and some models integrate safety control functions (SIL 3/PL e), supporting modular expansion and distributed deployment, balancing performance, space, and cost requirements.

Core parameters of the three major product families

KeControl C5 (Compact Modular)

Positioned as "modular distributed control", it is divided into CP 50x (compact version) and CP 5x0 (high-performance version), supporting left expansion card+right KeConnect C5 I/O module connection.

Model, processor, memory size (width x height x depth), power consumption, core characteristics

CP 503/A Intel Atom E3815 (1.46GHz single core) 1GB single channel 80 × 121 × 90.6mm 150W fanless, 1 × EtherCAT master station

CP 505/A Intel Atom E3827 (1.75GHz dual core) 2GB dual channel 80 × 121 × 90.6mm 154W with fan, multi interface integration

CP 507/A Intel Atom E3845 (1.91GHz quad core) 2GB dual channel 80 × 121 × 90.6mm 174W with strong graphics performance and support for passive panels

CP 507/C Intel Atom E3845 (1.91GHz quad core) 4GB dual channel 80 × 121 × 90.6mm 174W large memory, suitable for complex applications

CP 520/C Intel Celeron 3955U (2.0GHz dual core) 4GB dual channel 157.1 × 121 × 90.6mm 140W high performance, supports customized interface board

CP 530/C Intel Core i7-6600U (2.8GHz dual core) 4GB dual channel 157.1 × 121 × 90.6mm 150W top-level performance, suitable for image processing

Key features:

Module bus: Supports EtherCAT, output power 5V 30W/24V 48W

Standard interfaces: 2 x Gbit Ethernet, 1 x USB 3.0, 1 x DVI, 1 x CAN, 1 x RS232/485

Working environment: 0-55 ℃ (0-60 ℃ for CP 507/A), humidity 10-95% (no condensation)

KeControl C1 (Centralized High I/O)

Positioned as "high I/O density single machine control", specially designed for scenarios that require a large amount of local I/O, such as injection molding machines and extruders, with integrated rich interfaces.

Model Processor Memory Size (W x H x D) Power Consumption Built in I/O

CP 035/M Intel Atom E3815 (1.46GHz single core) 1GB single channel 415 × 137 × 55mm 35W 48DI, 56DO, 6AI, 4AO, 2TI

CP 056/E Intel Atom E3827 (1.75GHz dual core) 1GB dual channel 415 × 137 × 55mm 135W 48DI, 56DO, 8AI, 6AO, 10TI

CP 056/Y Intel Atom E3845 (1.91GHz three core) 2GB dual channel 415 × 137 × 55mm 140W as above, three core computing power improvement

CP 057/Y Intel Atom E3845 (1.91GHz quad core) 4GB dual channel 415 × 137 × 55mm 140W as above, quad core compatible with complex control

Key features:

Control functions: Fast Cut Off Reaction (switching accuracy 32 µ m @ 500mm/s), Fast Closed Loop Control

Standard interfaces: 1 x USB 2.0, 1 x USB 3.0, 1 x Gbit Ethernet, 1 x 100MBit Ethernet, 1 x DVI, 1 x CAN, 1 x RS232/485

Working environment: 0-55 ℃, anti vibration/impact in accordance with EN 61131-2

KeDrive D3 (Integrated Drive Type)

Positioned as "driver+control integration", adopting a driver form design, saving 76% of control cabinet space, supporting 1-3 axis expansion, including regular and safety control models.

Model, type, processor, memory size (width x height x depth), power consumption, core characteristics

D3-DU 330/A regular Intel Atom E3845 (1.91GHz quad core) 2GB dual channel 55 × 310 × 241mm 26W heat sink, 2 × EtherCAT main station

D3-DU 330/B regular Intel Atom E3845 (1.91GHz quad core) 2GB dual channel 55 × 310 × 188.5mm 26W ColdPlate heat dissipation

D3-DU 360/A regular Intel Celeron 3955U (2.0GHz dual core) 4GB dual channel 55 × 310 × 241mm 25W heat sink, 1 × EtherCAT/Circos III

D3-DU 360/B regular Intel Celeron 3955U (2.0GHz dual core) 4GB dual channel 55 × 310 × 188.5mm 25W ColdPlate heat dissipation

D3-DU 335/A Security Intel Atom E3845 (1.91GHz quad core) 2GB Dual Channel 55 × 310 × 241mm 25W Built in Security Control, 20SDI/8SDO

D3-DU 335/B Security Intel Atom E3845 (1.91GHz quad core) 2GB Dual Channel 55 × 310 × 188.5mm 25W ColdPlate Heat Dissipation+Security Features

D3-DU 365/A Security Intel Celeron 3955U (2.0GHz Dual Core) 4GB Dual Channel 55 × 310 × 241mm 60W High Performance+Security Control

D3-DU 365/B Security Intel Celeron 3955U (2.0GHz Dual Core) 4GB Dual Channel 55 × 310 × 188.5mm 60W ColdPlate Heat Dissipation+Security Features

Key features:

Safety function: The safety version supports SIL 3/PL e, with built-in 20SDI, 8SDO (0.5A), 2SDO (2A), 4TDO

Standard interfaces: 3 x USB 2.0, 2 x Gbit Ethernet, 1 x DVI, PCIe expansion

Working environment: 5-55 ℃, to be installed in IP54 protective cabinet

Expansion Cards and Accessories

Core Expansion Card

Model Type Core Parameters Dimensions (Width x Height x Depth) Compatible Products

NE 551 Gigabit Ethernet 2 x RJ45 interface, PCIe connection 26.5 x 106 x 82.5mm KeControl C5

FE 571 EtherCAT main station 2 x RJ45 interfaces, supporting star topology 26.5 x 106 x 82.5mm KeControl C5

FE 573 EtherCAT main station 2 x M8 interface, industrial protection 26.5 x 106 x 82.5mm KeControl C5

FE 560 multi protocol bus 2 x RJ45, supporting EtherCAT/PROFINET/EtherNet/IP 26.5 x 106 x 82.5mm KeControl C5

Key Accessories

Example of accessory type specifications for compatible products

Storage media XC 540/C (2GB MicroSD), D3-XC 350/A (4GB CFast) C5/C1, D3 series

Connecting cable XW 599-030 (3m Mini I/O cable), XW 020-050 (5m EtherCAT cable) full series

Terminal plug BCF3.81 4pos Push In (black), D3-XT 215/A (safety I/O connector) C5/C1, D3 safety version

Software license RL Motion (motion control), RL Robotics (robotics), KeStudio Engineering (programming) full range

Core Technologies and Functions

Real time communication and control performance

EtherCAT Master Station: FPGA hardware level implementation, cycle time of 62.5 µ s, data bandwidth utilization rate>95%, CPU load reduced by 20%

Core algorithms: Fast Reaction Control (reducing dead time of control loop by 66%), Fast Cut Off Reaction (injection molding machine switching accuracy of 32 µ m)

Multi task parallelism: Multi core CPUs support parallel execution of control tasks and visualization (KeView Style Multitouch) without real-time interference

Safety and Reliability

Safety level: KeDrive D3-3x5 series complies with EN ISO 13849-1 PL e, EN 62061 SIL 3, supports safety motion monitoring

Protection design: Protection level III (EN 61010-2-201), overvoltage category II, some models support IP54 protective cabinet installation

Data Security: CFast/MicroSD stores firmware, application, and process data, supports tool free backup and updates

Compatibility and Scalability

Hardware compatibility: Supports KeConnect C5 distributed I/O modules, third-party EtherCAT devices (with ESI files provided)

Software compatibility: Based on Linux, supporting OPC UA, PLCopen, robot programming and other standards, compatible with Industry 4.0

Customization capability: C5 series supports customized technology cards, C1 series supports direct drive of proportional valves, D3 series supports shaft expansion

Compliance and Support

Certification standards: CE (Electromagnetic Compatibility 2014/30/EU, RoHS 2011/65/EU), UL 61010-1/201, UKCA, KC (Korean EMC)

Technical support: Global branches (Austria, China, Germany, etc.), providing KeStudio programming software, firmware updates, technical documentation

Maintenance features: Built in service display screen (LCD/7-segment display), supports quick diagnosis and firmware upgrade, modular design for easy maintenance