KUKA KR C4 smallsize-2 small robot control cabinet

KUKA KR C4 smallsize-2 small robot control cabinet

KUKA KR C4 smallsize-2 Small Robot Control Cabinet Assembly Guide, aimed at engineering personnel with expertise in electrical and electronic, robot control cabinets, and Windows systems; The copyright of the document belongs to KUKA Deutschland GmbH and cannot be copied or disclosed to third parties without written permission. This control cabinet supports up to 6 servo axes. If you want to drive external axes (linear units, positioners), an additional KR C4 small-size drive box needs to be selected.

Product Description

The entire system consists of a robotic arm body, KR C4 smallsize-2 control cabinet, smartPAD teaching pendant, connecting cables, software, and optional components.

Core hardware of control cabinet

Drive unit DC: includes KPP_SR drive power supply, KSP_SR servo drive, generates intermediate circuit DC voltage, realizes motor and brake control, and monitors bus voltage in braking mode.

KPC Control PC: The motherboard supports D3236-K and D3445-K; Responsible for HMI human-machine interface, program editing and archiving, motion sequence control, path planning, drive circuit control, safety monitoring, and external device communication.

CCU_SR small robot cabinet control unit: The central power distribution and communication hub of the whole machine are composed of CIB_SR cabinet interface board and PMB power management board.

Integrate 9 secure inputs and 4 isolated floating outputs;

Battery backup power supply, save location data after power failure and then control shutdown;

Manage fans, temperature collection, main contactor, rapid measurement input, teaching pendant detection, calibration testing.

Low voltage power module: Provides power to the components inside the cabinet, with a green LED indicating the operating status.

Battery pack: Controlled shutdown achieved by power outage; Storage must be charged regularly according to the ambient temperature to prevent damage from over discharge.

Three sets of internal buses

Bus mounted devices

KCB library card controller bus driver unit, RDC, CIB_SR, EMD electronic calibration device

KSB library card system bus CIB_SR, SION, smartPAD SION, optional expansion SIB security board

KEB library card expansion bus, various fieldbus IO expansion modules (PROFIBUS, DeviceNet, EtherCAT, etc.)

Cooling system: two sets of cooling circuits; Internal control electronic components rely on controlling the heat exchange cooling of PC fans; The braking resistor, driving unit heat sink, and low-voltage power supply are directly cooled by ambient air using an external fan. It is strictly prohibited to install filter cotton on the ventilation opening, as it will increase the temperature and shorten the lifespan of the device.

Other components: Right DIN rail customer option installation position; Optional surge suppressors and wheel components; Casters are only allowed to move within the cabinet group for short distances and long-distance transportation is prohibited.

Hardware interface panel

X1 Harting main power interface;

X20 motor connector (maximum 6-axis motor+brake);

X11 Discrete Security Interface;

X19 smartPAD teaching pendant interface;

X21 RDC rotary converter data interface, supporting US2 switchable load voltage version;

X42 reference switch/calibration test interface;

X69 service interface, optional interface slot.

Important: Contactors, relays, and valve coils connected by customers must be equipped with freewheeling diodes, and RC circuits and VCR resistors cannot be replaced.

Technical data

Basic cabinet parameters

Cabinet color: RAL7016 charcoal gray on the side panel, orange on the cabinet door and storage card; Maximum 6 servo axes; Weight approximately 60 kg; protection level IP54; Noise<66 dB (A); The allowable load for uniform distribution on the top of the cabinet is 1500   N; the spacing for parallel installation is 50   mm.

Software version limitation: This control cabinet only supports KSS ≥ V8.3.20.

Power supply conditions

Rated three-phase input: AC 3 × 380/400/440/480   V; voltage tolerance ± 10%; Power 3.30 kVA; Frequency 49-61 Hz;

A power grid with grounded neutral must be used, and a transformer must be configured for ungrounded neutral;

Main circuit fuse: 3 × 16   A slow melting without external drive box; 3 × 32   A slow melting with drive box; System impedance ≤ 300   m Ω; short-circuit current 5   kA.

environmental conditions

Project parameters

Operating temperature+5...+45 ℃

Storage and transportation with battery -25...+40 ℃

Dismantling batteries for storage and transportation -25...+70 ℃

The maximum temperature change rate is 1 K/min

Do not reduce power when the altitude is ≤ 1000 meters; For every 1000-4000m increase, the power decreases by 5%

Battery storage charging cycle ≤ 20 ℃ every 9 months; 20-30 ℃ every 6 months; 30-40 ℃ every 3 months

Mechanical dimensions and installation

Cabinet appearance and appearance with casters; Install M8 screws with holes on the ground;

Minimum installation clearance: 300   mm above, 150   mm on the side, and 100   mm behind; maintenance accessibility must be ensured;

Support stacking installation (up to 2 control cabinets can be stacked, or paired with drive boxes); The caster version cannot be stacked.

CIB_SR safety interface electrical parameters

Safe output: ≤ 30   V; current 10   mA~750   mA; cable cross-section ≥ 1   mm ²; The maximum lifespan of 20 years is 100000 switches, and modules must be replaced if they exceed the cycle;

Safe input: 5-11V is an undefined transition zone; -3~5   V disconnection; 11-30V conduction; Maximum load per channel<15 mA; supports dynamic pulse testing TA-A/TA-B;

Cable: The maximum length of actuator cable is 50 meters; the maximum length of sensor cable is 50 meters.

Cable constraints

The smartPAD teaching pendant cable can be extended up to 2 segments, with a total length of ≤ 50 meters;

The length difference of cables in each channel of RDC is not allowed to exceed 10 meters.

REACH regulation

CR2032 button battery contains SVHC high concern substance: 1,2-dimethoxyethane (EGDME), CAS: 110-71-4.

Security Chapter

KR C4 smallsize-2 safety function meets EN ISO 13849-1 Category 3, Performance Level d; Require the emergency stop device to be pressed and tested at least once every 12 months.

Responsibility and Machinery Directive

Robots are partially completed mechanical equipment and cannot be produced separately; The complete system must be integrated, and the system integrator must issue an EC conformity declaration; The control cabinet has EMC and low voltage CE markings.

Without authorization from the library card, it is prohibited to modify software and hardware; Any damage caused by third-party installation of accessories shall be borne entirely by the user.

Define STOP0, STOP1, and STOP2 stop categories in accordance with EN60204-1.

Personnel Classification

Distinguish between system integrators, operators, maintenance and repair personnel, and cleaning personnel; All homework personnel must understand the document safety chapter; High risk operations can only be carried out by qualified personnel who have received specialized training.

Regional definition

Workplace: Robot motion range; Dangerous zone=workspace+robot arm/external axis stopping distance; The safety zone is outside the danger zone; It is necessary to physically protect the hazardous area and prohibit personnel from entering.

Stop distance measurement: The robot is equipped with actual tools and loads, and runs for about 1 hour to reach working temperature. STOP0 and STOP1 are tested multiple times, and the worst value is taken.

Operating mode

Mode function speed limit

T1 manual deceleration mode teaching, debugging, program verification maximum TCP 250 mm/s, overspeed triggers STOP0; Need to enable switch

T2 manual high-speed mode test operation allows for a speed higher than 250 mm/s, but teaching programming is prohibited

AUT automatic mode single machine automatic running program setting speed

AUT EXT external automatic mode, upper PLC control, automatic program running, set speed

Mode switching is not allowed to be executed during program execution and will trigger Safety Stop2.

Core security functions

Emergency Stop: The teaching pendant comes with an emergency stop function; The system must be additionally configured with an external emergency stop; Press to execute STOP1.

Three position enabling devices: three enabling switches on smartPAD; Release → STOP2; Completely press to death (panic position) → STOP1; Two enable switches can remain in the neutral position for a maximum of 15 seconds. It supports external enable devices.

Operator safety (safety door monitoring): only AUT/AUT-EXT is effective; Opening the safety door triggers STOP1; Restarting requires an external confirmation button and automatic confirmation is prohibited.

External safety signals: external safety operation stop, external safety stop 1, external safety stop 2; The X11 discrete interface only supports secure stop 2.

Additional protection: software limit switch, mechanical hard limit switch; Manual release of the brake without driving energy (for emergency use only, may damage the motor brake).

Safety points for various types of homework

General: It is strictly prohibited to stand under the robot arm; The power-off robotic arm may still fall and must be mechanically fixed; The safety function is strictly prohibited from removing the shield;

Transportation: Follow the transportation posture and avoid impact and vibration;

Power on debugging: Conduct a visual inspection of the entire machine and a comprehensive safety function test before powering on; After modifying machine data, it is necessary to perform machine data practical verification; Provide Startup mode, which can move the robot in T1 mode when external security protection is not installed. This mode blocks external protection and personnel must be isolated from the danger zone;

Manual mode: New/modified programs prioritize T1 testing; T2 mode is only used for high-speed testing, and all personnel must be outside the danger zone;

Simulation: The simulation generates a program, and the physical machine must be tested in T1 mode;

Automatic mode: All protections are intact, and there is no one in the danger zone;

Maintenance and repair: power off, lock and tag; After a power outage, the residual voltage in the intermediate circuit can reach up to 780 VDC and requires waiting for discharge; ESD anti-static; Balance cylinder belongs to pressure equipment;

Retirement, storage, and disposal: comply with local regulations;

Single point control SPOC security: Submit interpreter PLC、OPC、 Remote tool access robot restrictions; In T1/T2 mode, the access robot must satisfy (USER_SAF=TRUE, ) SPOC_MOTION-ENABLE=TRUE; Prohibit backend rewriting of security related variables such as $OVePr (speed multiplier).

Reference standards

Mechanical Directive 2006/42/EU, EMC Directive, Pressure Equipment Directive, ISO 10218-1, ISO13849-1/2, ISO13850, EN60204-1, etc.

System Planning

EMC electromagnetic compatibility: All external cables use shielded cables, and the shielding layer is extensively pressed onto PE rails; The control cabinet belongs to Class A industrial equipment.

Power supply conditions: must be grounded to a neutral power source; Suggested leakage protector: universal current type, selective, 300 mA;

X11 Discrete Safety Interface (standard for this control cabinet)

Dual channel safety interface with TA-A and TA-B dynamic pulse test outputs, achieving Cat.3 PL d;

Support external emergency stop, external enable switch, safety door, operator safety confirmation Safe‑Stop2、 Safe operation stopped;

Provide wiring schematic: external emergency stop circuit, safety door+confirm button, safety input/output wiring timing pulse diagram.

US2 can switch 24V load voltage: three configurations: external PLC control, KRC robot controller control, disabled; After each startup, safety configuration change, and contactor replacement, the US2 function must be verified; The US1 and US2 cables must be isolated to prevent dangerous situations caused by short circuits.

Equipotential PE grounding: 4mm ² equipotential cable from the robotic arm to the control cabinet; Use 16mm ² cable for the equipotential bus from the drive box version to the workshop.

Safe PFH failure rate: KR C4 smallsize-2 PFH<1 × 10 ⁻⁷, based on a 20-year service life; Pre emergency testing every 12 months.

Transportation

Three transportation options:

Lifting equipment: Power off, unplug all cables, and close the cabinet door; Use 4 M8 suspension rings, with priority given to the suspension frame; Prohibit inclined hoisting; The lifting speed is slow to prevent swinging.

Tray forklift: Fixed on a pallet for transportation.

Wheel transportation: limited to short distance translation within the cabinet group, cannot be transported over long distances, vehicle dragging is prohibited, there is a risk of tipping.

Power on and restart

Complete startup process

Place the control cabinet horizontally to meet the minimum clearance and inspect for transportation damage; Confirm that there is no condensation inside the cabinet;

Cable laying: Separate the wiring of motor cables and data cables; To replace the RDC data cable, all axes must be recalibrated; Comply with the bending radius of cables;

Connect PE equipotential protection grounding;

Restore battery discharge protection plug X305 (factory disconnected to prevent depletion of transportation and storage batteries);

Harting X1 is connected to the three-phase main power supply;

Hardware replacement: Replace hardware of the same model directly; Replacing hard drives, adding/removing hardware, and replacing different models of hardware must be done using WorkVisual to regenerate and download project configurations;

Enable Startup mode as needed;

Confirm that there are no people in the danger zone and all safety equipment is in good condition; Close the main switch, release the emergency stop, and the system will start.