KUKA KR C4 Midsize Assembly Guide

Battery maintenance is often overlooked. If the storage temperature is not higher than+20 ℃, charge once every 9 months; +Every 6 months from 20 to+30 ℃; +30 to+40 ℃ every 3 months. Before the first start-up, the X305 connector on the CCU needs to be plugged in to release the battery discharge protection during transportation.

Security Chain: Logic of X11, X66 and STOP 0/1/2

The safety controller of KR C4 midsize is located inside the control PC and is responsible for switching drivers, applying brakes, monitoring brake slopes, monitoring stillness, monitoring T1 speed, evaluating safety signals, and setting safety outputs. The safety functions include operation mode selection, operation safety, emergency stop, enabling device, external safety operation stop, external safety stop 1, external safety stop 2, and T1 speed monitoring. Installing flanges at a speed exceeding 250 mm/s under T1 will trigger a safety stop of 0.

Safety stop is divided into safety STOP 0, safety STOP 1, and safety STOP 2. STOP 0: The safety controller immediately cuts off the driving and braking power supply; STOP 1 is executed by the non safety part for braking, monitored by the safety controller, and the power supply for driving and braking is cut off after the robot stops; After STOP 2 braking, the driver remains activated, the brake is released, and it switches to safe operation stop monitoring. Understanding these differences is crucial for troubleshooting "why cannot reset" and "why drive enable is lost".

There are two types of secure interfaces: discrete secure interface X11 and Ethernet secure interface X66, which cannot be used simultaneously. X11 is internally connected to SIB, including test output A/B, external E-STOP, local E-STOP, operation safety, operation safety confirmation, safety run stop, safety stop 2, peripheral enable and other pins. The secure input adopts a dual channel design and is detected through testing pulse cycles. The test outputs TA_S and TA_S are alternately turned off, with a turn off pulse length of about 625 μ s, a single channel turn off cycle of about 106 ms, and a two channel offset of about 53 ms. Floating contacts must be used for wiring, and the test output can only be used for SIB input and cannot be connected to other power sources externally.

Ethernet safety interfaces are commonly used for PROFIsafe or CIP Safety. The input byte includes external E-STOP, operation safety, operation safety confirmation, safety stop 1/2 US2、 Signal to stop safe operation; Output byte feedback on external E-STOP status, operation safety confirmation, safety stop status, safety interface activation, and system power outage request. It is recommended to preset the reserved space to 1 to avoid accidental shutdown caused by the accidental activation of new security features after software upgrade.

In terms of safety performance, the controller's safety functions comply with Category 3 and Performance Level d of EN ISO 13849-1, and the PFH value is usually less than 1 × 10 ⁻⁷. The premise is that the E-STOP device should be tested at least once every 12 months. The system integrator must complete risk assessment, safety fence, safety gate, external E-STOP, and enable device design, and cannot treat the controller itself as a complete safety system.

Motor, power supply, and data interface: wiring errors are more dangerous than parameter errors

The motor connectors include combinations such as X20, X20.1, X20.4, X7.1 to X7.8, X81, X82, etc. Typical pin definitions include motors U1, V1, W1, brake 24V, and brake 0V. Motor cables must be laid separately from data cables to avoid interference. The fixed installation bending radius is 3 to 5 times the cable diameter, and the drag chain installation is 7 to 10 times. The total length of motor cables usually does not exceed 50 meters. The cable cross-sectional area should be at least 1 mm ².

RDC data cable connected to X21, smartPAD connected to X19. X19 includes data pairs, smartPAD insertion recognition, 24V, and GND. If smartPAD is disconnected, the E-STOP on it is no longer valid, so the system must have at least one external E-STOP. The power supply is connected through the X1 Harting connector, with pins L1, L2, L3, and PE. If the rated voltage is higher than 400 V and no transformer is used, the power cable needs to be shielded, and the shielding layer should be grounded at least at one end.

The external 24V power supply must use a safely isolated PELV power supply, rated at 27 V, with a range of 18 to 30 V, a continuous current greater than 8 A, a cable cross-sectional area of at least 1 mm ², a length less than 50 m, or a total line length less than 100 m. The negative pole of the external power supply must be grounded by the customer and must not be connected in parallel with basic insulation equipment. The contact voltage of the SIB output power supply should not exceed 30 V, with a minimum current of 10 mA and a maximum current of 750 mA. The standard SIB switch frequency should be less than 100000 times within a 20-year lifespan, and the extended SIB should be less than 780000 times. If exceeded, the module must be replaced.