KUKA Sunrise Cabinet Next Generation Small Control Cabinet

KUKA Sunrise Cabinet Next Generation Small Control Cabinet

Sunrise Cabinet is a new generation of small control cabinet from KUKA, used for LBR iiwa series sensitive collaborative robots, running the Sunrise. OS system; Supports independent landing or 19 inch standard cabinet rack installation, with CCU_SR small robot control unit as the hardware core, aimed at engineers with professional backgrounds in electrical, robotics, and Windows.

Product Description

Complete system: LBR iiwa collaborative robotic arm+Sunrise Cabinet control cabinet+smartPAD teaching pendant+cables+Sunrise. OS software+options.

Core hardware unit

KPC control PC, supporting three motherboards: D3076-K/D3236-K/D3445-K; Responsible for human-machine interface, program processing, path planning, driver control, safety monitoring, and external device communication.

CCU_SR Small Robot Cabinet Control Unit (CIB_SR+PMB_SR): complete machine power distribution, internal bus communication, safety IO, fan and temperature monitoring, main contactor control, Mastering calibration, high-speed measurement input; Power outage relies on backup battery storage location and controlled shutdown, load testing battery health status.

EDS electronic data storage card, storing robot configuration and origin data.

Low voltage power supply unit, backup battery pack, power filter; Braking resistor.

Bus system

KCB controller bus; KSB safety bus; KEB expansion bus;

Main interfaces

X11: 50 pin D-Sub dual channel safety interface;

X65: EtherCAT expansion bus;

X66: KLI upper communication;

X69: KSI service network port;

X650 medium flange interface: specifically designed to provide 48V/24V power and data communication for iiwa wrist.

Cooling architecture: single loop fan cooling; Do not install filter cotton on the ventilation opening, as it may overheat and shorten the lifespan of the device.

Installation form: independent floor installation, also supports installation in 19 inch industrial racks; The rack depth requirement is ≥ 600mm; the minimum ventilation gap between the left and right sides of the cabinet is 70mm.

Optional accessories: smartPAD installation bracket; Transport the handle bracket.

Technical Data

Mechanical parameters: The total weight of the machine is about 23 kg, and the protection level is IP20; The noise is about 54 dB (A); Dimensions and 19 inch rack openings; Installation holes for smartPAD bracket and handling handle.

Electrical parameters: single-phase 110/230   V AC, ± 10%, 50/60   Hz; fuse 2 × 15   A slow melting C type; External PELV-24V power supply DC 27.1 V; smartPAD cable can be extended in up to two sections, with a total length of ≤ 50 m.

Environmental conditions: working temperature of 5-45 ℃; Storage -25~+70 ℃; Power derating at altitudes greater than 1000 meters; Vibration and impact indicators.

CIB_SR safety board electrical characteristics: Input OFF interval -3-5   V, ON interval 11-30   V, 5-11   V is an undefined transition zone; Dual channel dynamic test output TA-A/TA-B; Pulse timing t1=625 μ s, period t2=106 μ s; maximum cable length 50 μ m.

Safety performance: compliant with EN ISO 13849-1 Cat.3/PL d; SIL2; PFH＜1×10⁻⁷； The safety components require at least one functional test per year, with a designed service life of 20 years.

Nameplate and warning label: including electric shock warning, warning to disconnect the main power before opening the cover. The nameplate is strictly prohibited from being painted or removed.

REACH regulation SVHC substance description.

Security

EC Machinery Directive; Robots belong to "partially completed machinery", and system integrators are responsible for the overall risk assessment of the machine; Unauthorized modification of software and hardware will result in loss of warranty.

Personnel classification: system integrator, maintenance personnel, operator, all personnel must read the safety chapter.

Dangerous zone: robot workspace+braking stop distance; To stop distance testing, actual tool load is required, and the equipment is tested after running in a hot state, taking the worst-case scenario.

Operating mode (different from KR C4, with the addition of CRR mode)

Mode description

T1 manual deceleration mode; Program validation maximum 250 mm/s; Manual guidance mode is not limited by the 250 mm/s limit and relies on safety monitoring

T2 manual high-speed mode,>250 mm/s, cannot jog Jog

AUT local automatic mode

CRR controlled robot return mode: After the robot stops due to safety monitoring triggering, this mode can be used to move the robot and release the safety monitoring alarm

Switching modes during operation will trigger the Safety stop1 path to maintain braking.

Stop category

Safety stop1 (path maintenance braking): The safety controller monitors the braking process and cuts off the drive and closes the brake no later than 1 second.

Safety devices

Emergency stop; Three level enable switch; The middle position allows for movement; Fully press the panic position to trigger STOP1; Release the trigger STOP1;

Support multiple external enabling devices, allowing multiple people to enter hazardous areas for use; External emergency stop, external safety door, external Safe operational stop static monitoring input.

T1 mode 250 mm/s: By default, this 250 mm/s is not a safety level monitoring device; To achieve safety level speed monitoring, the corresponding safety option needs to be activated. The maximum speed of manual guidance needs to be determined through risk assessment.

Multiple protections: software limit, mechanical hard limit; It is prohibited to manually drag the cooperative arm without driving energy (unlike traditional robots, the iiwa joint has a built-in torque sensor).

Stop triggering is divided into two categories: permanently fixed triggering conditions (non modifiable) and user configurable triggering conditions.

SPOC single point control principle: Submit, PLC, OPC, remote tools, Workbench online configuration, safety constraints need to be implemented, and it is prohibited to rewrite motion related variables in the background to cause unexpected motion; T1/T2 mode prohibits modifying programs and outputs through the background.

Key safety points for working conditions

Debugging: Change default password; After the machine data is changed, it must be verified through practical operation;

Manual mode: New/modified programs prioritize T1 mode testing; Multiple people entering the protected area are equipped with independent external enablement for each person;

Repair and maintenance: power off and lock; Disconnect the main power supply; Follow ESD anti-static measures; Some components remain live even after power failure;

Reference the complete set of EU/international standard lists (2006/42/EC Machinery Directive, EN ISO 13849-1, EN 60204-1, etc.).

Planning and Design 

EMC electromagnetic compatibility: Shielded cables are used for external cables, and the shielding layer is extensively crimped with PE bars; Class A industrial equipment.

Installation conditions: Independent floor standing/19 inch rack installation; Rack depth ≥ 600mm; left and right ventilation gap ≥ 70mm.

PE equipotential grounding is mandatory, and the control cabinet body must be connected to the on-site PE protective grounding busbar.

Power supply: single-phase AC power supply; Recommended leakage protector 300 mA, universal current type, selective.

X11 50 pin D-Sub secure interface

Dual channel dynamic pulse test TA-A/TA-B;

Signal: external emergency stop, operator safety door, external safety stop1; Support multiple external enablement channels;

Provide wiring schematic: emergency stop circuit, safety door wiring; Floating contact safety input and output; Dynamic pulse timing diagram;

The safety door must be equipped with an external confirmation button to prohibit automatic reset and operation when closing.

X65 EtherCAT expansion bus; X66 KLI； X69 KSI service port; X650 medium flange interface, specifically designed for iiwa wrist power supply and communication.

Hardware changes: To replace hard drives, boards, add or remove peripherals, Sunrise Workbench software must be used to complete system configuration.

Transportation

Power off before transportation, remove all cables, and close the cabinet door; Vertical transportation;

Support lifting rings and pallet forklift handling;

Do not drag or tilt; Inspect the appearance and fasteners upon completion of transportation.

Chapter 8 Startup and Re Debugging

Complete process of power on:

Visually inspect and confirm that there is no condensation inside the control cabinet;

Install in place to meet the minimum ventilation gap;

Connect the mechanical arm cable and X650 wrist medium flange cable; Comply with the bending radius of cables;

Install the smartPAD bracket and plug in the teaching pendant;

Connect PE equipotential protection grounding;

Restore battery discharge protection plug X305;

The X11 safety interface must be plugged in when the power is turned off;

Connect to the main power supply; Distinguish between two wiring methods with and without Mains connectors; Strictly distinguish the L/N/PE wiring colors for versions without connectors;

After the hardware change, Sunrise Workbench downloads the project configuration;

Clear the dangerous area of personnel and objects, release the emergency stop, close the switch and turn on the power;

Complete verification of all safety equipment functions.

Unplug the teaching pendant and the emergency stop of the machine will fail; Reconnect and wait for about 30 seconds. The emergency stop and third gear enable switches must be retested.

Equipment Operation

SmartPAD teaching pendant panel instructions: emergency stop, mode knob, 6D space mouse, touch button override、 Start stop, user-defined buttons; Rear three gear enable switch.

USB only supports FAT32 format USB drives for archiving and recovery purposes.

In T1/T2/CRR mode, the enable switch must be kept in the middle gear before the machine is allowed to jog; The AUT mode enable switch is invalid.

Maintenance

Maintenance of safety prerequisites: power off and lock, disconnect the incoming power supply; ESD anti-static; Do not blow compressed air directly into the cabinet.

maintenance cycle

Annual: Complete inspection of CCU_SR relay output; Complete functional testing of all emergency stop and enable switches;

Clean the fan according to the condition of dirt and stains;

Battery monitoring alarm, replace battery packs in pairs;

The button battery on the motherboard is replaced regularly.

Maintenance homework:

CCU_SR relay output function verification;

Cleaning: Vacuum cleaner+soft cloth solvent-free cleaner; Do not spray water or blow with compressed air;

Complete maintenance and check for worn fuses, plugs, grounding, and cables.

Maintenance and Replacement

Maintenance must be carried out by qualified personnel trained in KUKA; Prioritize original factory spare parts; The high-strength 10.9 screw should be replaced after disassembly and cannot be reused. Each repair includes: safety prerequisites, tool list, step-by-step disassembly and assembly, connector definition, and functional testing after replacement. List of replaceable parts:

Cabinet fan components;

KPC complete set, PC fan, motherboard button battery, SSD solid state drive; After replacing the SSD, it is necessary to install Sunrise. OS and restore the configuration through Workbench;

CCU_SR small robot control unit; Pay attention to the connector unlocking mechanism during disassembly and assembly, and prohibit violent plugging and unplugging;

Backup battery packs must be replaced in pairs; Battery storage replenishment cycle: ≤ 20 ℃ every 9 months; 20-30 ℃ every 6 months; 30-40 ℃ every 3 months to prevent damage from over storage;

Low voltage power supply unit; Power filter; Braking resistor;

Sunrise. OS system software installation.

Troubleshooting

CCU_SR board complete set of LED indicator lights: power supply, KCB/KSB bus, EtherCAT safety node, fuse LED; Different colors/flicker frequencies correspond to fault phenomena and corresponding solutions;

CCU_SR all fuse numbers, rated currents, purposes, and corresponding LED prompts for fuses;

Interpretation of Link Activity status for each network port;

Troubleshooting process: Check the power supply, fuses, and wiring; Disconnect the external device and restart it; Replace the CCU_SR module despite the malfunction.

Shutdown, Storage, and Scrap Disposal

Shutdown and return: Disconnect all peripherals and mechanical arm cables, disconnect the grounding wire, and prepare for transportation;

Long term storage: indoor dry and dustproof, no condensation; Remove the battery and seal the interface casing for protection; Strictly adhere to the regular battery recharge cycle;

Scrap and disassembly: classified by material; Waste batteries are returned to suppliers for recycling as hazardous waste, and the disposal of household waste is prohibited.