KUKA KR C5 micro controller

KUKA KR C5 micro controller

Product Description 

Complete set of robot: robotic arm body+KR C5 micro controller+smartPAD pro teaching pendant+cables+iiQKA.OS software+options. The controller is divided into two main units: Control Unit and Drive Unit.

Hardware composition

Control Unit Control Box

Mini CSP panel: mode, operation, fault LED, soft power button;

SYBperf Performance Edition system motherboard, microSD card (storage robot configuration), SSD hard drive;

IFBstd standard interface board: provides 16 non secure digital inputs and 16 non secure digital outputs.

Drive Unit Drive Box (KSP-300)

Built in fan cooling, FCU-300 power unit, SCU-6-1S safety control unit;

Generate DC intermediate circuit bus voltage, control motor and brake, monitor brake bus voltage.

The outer shell of the drive box is strictly prohibited from being opened without authorization, as there may be fatal high voltage.

All interfaces (front and rear panels)

Front interface

XFUSB1/2 USB3.0； XGSD microSD card slot; XGDP DP display output;

XG19: SmartPAD Pro teaching pendant interface;

XG12:16 input/16 output non secure IO, supporting high/low side jumper switching;

XD12/XD12.1:24V PELV peripheral power supply input/output;

XD20.1/XD20.2 motor connectors: drive A1-A3 and A4-A6 axis motors and brake respectively;

XG11.1 safety interface: 2 safety inputs, 1 safety output (dual channel with TA-A/TA-B dynamic pulse testing);

XG58 safety interface: additional 2 safety inputs for external enable and additional external emergency stop;

XF21: RDC/TPC robotic arm data interface; XG33: Fast measurement input+Drives ready indicator light output.

Rear interface

XD1: Single phase AC main power input (C15 high-temperature socket); XD2:24V UPS/cascade interface; Equipment power switch; Input fuses F1/F2.

XF1-XF8 Ethernet group

XF1 KSI service port; XF2 KLI‑IT； XF3/XF4 Daisy Chain Cascade; XF5/XF6 KLI‑OT； XF7 KONI option network port; XF8 KEI EtherCAT。

Cooling and installation form

Dual fan air cooling; Bottom air inlet, rear air outlet, and air duct must not be blocked;

Support: Horizontal placement, vertical placement on the side wall, stacking up to 3 units, wall mounted, 19 inch rack installation;

Misuse List: Prohibited for use as a platform, outdoors, explosion-proof, radioactive, underground mining, misuse results in loss of warranty.

Security Chapter 

The controller belongs to partially completed machinery and cannot be directly put into production. The system integrator shall conduct a risk assessment and issue an EC compliance statement; Safety performance EN ISO 13849-1 Cat.3/PL d, PFH<1 × 10 ⁻⁷, design life of 20 years; Emergency stop and enable switches must undergo functional testing at least every 12 months.

1) Stop category

STOP 0: Immediately cut off the drive and power on the brake;

STOP1 (path keeping): Cut off the drive after the controlled braking stops;

STOP1 (HRC collaborative mode): Smooth damping deceleration, maximum 1-second cut-off drive;

STOP2: Drive remains powered on, static monitoring.

2) Operation mode

Mode Usage Speed Limit

The T1 manual deceleration mode teaching and debugging program defaults to a maximum TCP of 250 mm/s; Manual guidance is not subject to this restriction and is limited by safety configuration

AUT automatic mode automatically runs the program and sets the speed

After triggering the safety monitoring of the CRR controlled robot's return mode, the lock is released for fault reset. The mobile robotic arm follows the T1 speed rule

3) Key safety functions

Emergency stop

Local emergency stop: Emergency stop on smartPAD pro; If the teaching pendant is unplugged, the emergency stop will fail; The system must be configured with an external emergency stop; Trigger the execution of STOP1 path to maintain shutdown;

XG11.1 configuration external emergency stop input; XG11.1 provides a local emergency stop relay output.

Three position enabling device: SmartPAD Pro with multiple sets of three position enabling devices; Median mobility; Release/fully press to death (panic position) to trigger STOP1; Support XG58 external enablement.

Operator safety (safety door): AUT mode is activated, and opening the safety door triggers STOP1; Prohibit automatic reset of door closing, external confirmation button is required.

HRC human-machine collaborative monitoring (iiQKA. OS V1.1 onwards): collision detection (30Nm), collaborative speed limit of 500 mm/s; Only reducing the risk of transient contact cannot eliminate the risk of compression, and ISO/TS 15066 still needs to be followed.

Additional protection: software limit switch; Manual release of the brake without driving energy (limited to rescue, may damage the motor brake).

SPOC single point control: Native implementation of the system, only smartPAD pro can control the robot without additional configuration.

4) IT Network Security (This chapter is lengthy and focuses on iiQKA.OS)

Network partition model: divided into OT production network, IT information network, KSI service port, isolated by firewall; Prohibit KSI from accessing the enterprise LAN.

safety measures

Physical access control; The factory default password must be changed; Graded automatic logout (administrator 5-minute, operator 30min);

USB only allows trusted devices; SSH service is disabled by default and can only be temporarily enabled. It will automatically shut down after 30 minutes; Developer mode can temporarily enable SSH;

Built in firewall; Communication TLS 1.2/1.3 encryption; Software update verification RSA4096 signature; Prohibit downgrading and installing old versions of the system; Component permission isolation, pruning non essential services.

When scrapping, it is recommended to remove the SSD and physically destroy it, as the controller does not have a one click secure erase.

5) Key points for homework safety

After a power outage, the maximum voltage in the intermediate circuit is 800 VDC. It is necessary to wait for at least 5 minutes for discharge before opening the cover for maintenance; Strictly implement the 5-step method for electrical safety; ESD anti-static;

New programs/modified programs must prioritize T1 mode testing; The physical machine for downloading simulation programs must undergo T1 verification;

Maintenance and repair must be powered off, locked, and tagged; If live operation is necessary, only T1 mode is available, emergency stop remains available.

Technical Data

Basic Electrical

Maximum servo axis: 6 axes; Weight approximately 9.8kg; IP20; Noise<54dB (A);

Power supply: single-phase AC 200-240V ± 10%, 50-60Hz; also supports two-phase grounded star grid with 2 phases; Apparent power of 1.30 kVA; Leakage current ≤ 10   mA; Equipment side fuse 2 × 10A slow melting C-type;

Environmental temperature: Operating at -5~+45 ℃; Storage -20~+60 ℃; No condensation;

Altitude: ≤ 2000 meters without power reduction; Reduce capacity by 5% for every 1000 meters between 2000-3000 meters;

Vibration shock: Running continuously for 3g, shock 10g (half sine 11ms).

Safety IO electrical parameters

Safe output: maximum 30V, 10-500mA; The cable has a maximum length of 50 meters and a lifespan of 20 years with a maximum of 9.5 million switches. The module will be replaced upon expiration;

Safe input: 5-11V is an undefined transition range; ≤ 5V disconnection, ≥ 11V conduction; Dual channel dynamic pulse TA-A/TA-B cyclic detection.

Mechanical dimensions and installation clearance

Controller body (excluding stress relief plate) 300  × 410  × 137   mm; with stress relief plate 513   mm depth;

Independent placement: minimum gap between inlet and outlet air is 100mm;

Install into protective cabinet: The distance between the air inlet and the inner wall of the cabinet should be ≥ 150mm; the distance between the air outlet and the inner wall of the cabinet should be ≥ 100mm;

Installation method: Horizontal, side wall vertical, stacking up to 3 units, wall mounted, 19 inch rack; The lower controller must be fixed to the ground during stacking.

REACH regulation: Information on SVHC substances of high concern can be accessed through KUKA Xpert; The nameplate warning label is strictly prohibited from being torn off.

System Planning 

EMC electromagnetic compatibility: EN55011 Class A Group 1 industrial equipment; All external communication cables must be shielded, with the shielding layer extensively grounded.

Installation requirements

Prohibit conductive dust and condensation environment; Under harsh working conditions, it must be installed in a cabinet with at least IP54 protection;

Wall mounted installation: The air inlet is located at the bottom, ensuring ventilation at the bottom and adding drip protection.

PE equipotential grounding

Manipulator ↔ Controller: 4mm ² copper wire; The controller is connected to the main PE row in the factory area, with a recommended area of 4mm ²; Both the front and rear shells are equipped with PE terminals.

Cable laying

Fixed wiring bending radius ≥ 3-5 times the outer diameter of the cable; Drag chain ≥ 7-10 times;

Separate the wiring of motor power cables and signal data cables;

The maximum allowable length of the entire set of cables for the robotic arm is 25 meters; after replacing the XF21 RDC/TPC data cable, all axes must be recalibrated for mastering.

Power supply requirements: must be grounded to the neutral TN power grid; Recommend B-type selective 30mA leakage protector.

Detailed interface definition

XG11.1 and XG58 have dual channel safety inputs, relying on TA-A/TA-B alternating 600 µ s pulses to detect line faults; Only passive floating contacts are allowed, and independent power sources cannot be connected externally;

XG12 non safety IO can switch high/low side modes with a set of jumper wires for 8 channels;

XF21 (RDC/TPC) provides 27V power supply for the robotic arm;

The Daisy Chain cascade interface is used to connect multiple KR C5 micro controllers in series.

Safety performance: PFH<1e-7, Cat. 3 PL d, meeting a 20-year lifespan requires regular safety function testing.

Transportation

Unplug all cables and close the casing cover; Horizontal placement of hand carts for transportation; Ensure proper anti fall fixation to avoid impact and vibration; Prohibit savage falls.

Startup and restart

Complete startup process

Visual inspection of transportation damage; Confirm that there is no condensation inside;

Choose installation method (independent/stacked/wall mounted/19 inch rack), fix the controller, and ensure ventilation clearance;

Connect the robotic arm to the controller's PE equipotential and ground the main PE;

Connect the motor cable and XF21 robotic arm data cable; All stress relief plates fix cables to eliminate pulling and pulling;

Connect SmartPAD Pro to XG19;

Configure and wire safety interfaces XG11.1 (external emergency stop, safety door) and XG58 (external enable); The security interface XG11.1/XG58 must be powered off and plugged in, and hot plugging is prohibited;

XD1 is connected to a single-phase main power supply;

Confirm that there are no people in the danger zone and all safety measures are in place; Close the power switch of the device;

Startup sequence: Restore USB drive → External hard drive → Internal SSD; Identifying external hard drives will disable built-in SSDs;

IiQKA.OS software debugging: no-load calibration, load calibration, TCP calibration, load data input, software limit, IO interface configuration.

Operation

Soft power button: Short press to shut down normally; Press and hold for ≥ 5 seconds to force a hard power outage (avoid as much as possible, there is a risk of damaging the system);

Power off operation of the whole machine: Disconnect the device switch and unplug the XD1 power cord.

Maintenance

Forcefully wait for at least 5 minutes for the intermediate circuit to discharge after power failure; ESD protection for all maintenance operations; Do not spray compressed air for cleaning.

maintenance cycle

Every 12 months

Complete functional testing of all emergency stops and all enable switches (including a 3-second shutdown test by pressing the panic position);

Drive ready indicator light function test;

Depending on the degree of dirt: clean the intake and exhaust grilles;

10 years: Replace the CR2032 button battery on the motherboard.

Test points

Enable switch test: When operating the robot in T1 mode, fully press and hold the enable button for 3 seconds. The robot must immediately stop without any errors;

Drives ready light: T1 mode remains enabled and the light is on; Press the panic button and the light will turn off.

Repair 

Only the document describes that on-site maintenance is allowed for the project, and the rest must be trained by KUKA personnel; KUKA original spare parts must be used. Can replace components on site (unified process: power off → unplug power cord → wait for 5 minutes for discharge → ESD protection → disassemble and replace → restore → power on test)

Stress relief plate;

19 inch rack mounting frame;

SSD hard drive;

System motherboard button battery (BIOS reset date and time after replacement);

Rear input fuse F1/F2;

SYBperf system motherboard (two versions: standalone version/4CAB cabinet version);

IFBstd standard IO interface board.

Before disassembling the motherboard/interface board, the microSD card and SSD hard drive must be removed first; Pay attention to the vertical connection plate to prevent breakage.

Troubleshooting 

The system motherboard is equipped with a red fault LED, which can be observed through the air inlet; Hardware LED error occurs, power is cut off, unplug the power cord, and contact KUKA technical support.

Discontinuation, storage, and disposal

Retired shutdown: Power off, unplug all cables, and remove all external wiring;

Storage: Indoor dry and dust-proof; Dismantle the battery and store it separately; Seal the interface and use a dust cover and desiccant; Avoid condensation;

Scrap: Circuit boards are used as electronic hazardous waste; Lithium batteries/button batteries should be recycled separately, and it is strictly prohibited to dispose of household waste; Metal classification and recycling after disassembly.