KUKA KR C4 compact robot controller

Ethernet Safety Interface X66: Supports PROFIsafe or CIP Safety protocols, communicates with upper level safety PLCs through standard RJ45 connectors, and can transmit safety input/output, monitoring area selection, tool selection, and other signals.

Both interfaces meet the requirements of SIL2 (IEC 62061) and Cat.3 (EN ISO 13849).

3.3 Overview of Security Features

The built-in safety functions of the controller include:

Operation mode selection (T1, T2, AUT, AUT EXT)

Operator protection (safety door monitoring)

Emergency stop (local and external)

Enable switch (three-level enable)

External security stops 1 and 2

External safety operation stopped (static monitoring)

T1 speed monitoring (250 mm/s)

Safety options (such as SafeOperation) can additionally monitor axis space, Cartesian space, velocity, acceleration, etc

3.4 Performance level and PFH value

The PFH value (hazard failure probability per hour) of KR C4 compact is less than 6.37 × 10 ⁻⁸, meeting the PL d requirement. This value is based on a 20-year service life and requires emergency stop equipment to be tested at least once every 12 months. In multi robot collaborative systems such as RoboTeam, the system integrator needs to evaluate the combined PFH value to ensure that it does not exceed the limit of PL d.

Chapter 4 Technical Parameters

4.1 Basic Parameters

Parameter values

Chassis type 19 inch rack mounted

Color RAL 7016

Maximum number of control axes 6

Weight 33 kg

Protection level IP 20

The average noise level is 54 dB (A)

4.2 Power Connection

Parameter values

Rated voltage 200 V -230 V AC, single-phase or two-phase (neutral grounded)

Voltage tolerance: Rated voltage ± 10%

Power frequency 50 Hz ± 1 Hz or 60 Hz ± 1 Hz

Rated power 2 kVA (see nameplate)

Maximum heat loss of 400 W

External fuse 2 × 16A slow melting (C-type)

4.3 Environmental conditions

Parameter values

Operating temperature+5 ° C to+45 ° C

Storage/transportation temperature (with battery) -25 ° C to+40 ° C

Storage/transportation temperature (without battery) -25 ° C to+70 ° C

Temperature change rate ≤ 1.1 K/min

Humidity level 3k3 (DIN EN 60721-3-3)

No derating for altitudes ≤ 1000 meters; 1000 m -3000 m, 5% reduction per kilometer

4.4 Cable length limit

SmartPAD cable: Use up to two extension cords, with a total length not exceeding 50 meters.

Rotary cable: The cable length difference between each channel of the RDC box shall not exceed 10 meters.

4.5 Battery Maintenance

To prevent deep discharge from damaging the battery, it is necessary to charge it regularly according to the storage temperature:

≤ 20 ° C: Charge once every 9 months

20 ° C to 30 ° C: Charge every 6 months

30 ° C to 40 ° C: Charge every 3 months

Chapter 5 Planning and Installation

5.1 Electromagnetic Compatibility (EMC)

The controller meets the requirements of EN 55011 Class A and is suitable for industrial environments. All external connection cables must use shielded cables and ensure that the shielding layer is connected to the PE busbar over a large area through shielding clamps.

5.2 Installation conditions

The controller can be installed horizontally or vertically, and it is recommended to place it horizontally.

If installed in a 19 inch cabinet, the depth of the cabinet should be at least 700 mm.

A ventilation gap of at least 70 mm must be maintained on both sides.

5.3 Power Connection

The power system must be connected to the neutral grounding point. The randomly attached device connection cable provides two options: with power plug or without power plug. It is strictly prohibited to plug or unplug the X11 connector while it is powered on.

5.4 Example of Safety Interface Wiring

X11 emergency stop circuit wiring: External emergency stop contacts should be connected in series to pins 2 (channel A) and 11 (channel B) of X11, and coordinated with test output pins 1 and 14 to achieve dual channel dynamic detection.

Safety door wiring: The safety door switch contacts are connected to pins 4 (operator protection channel A) and 6 (operator protection channel A confirmation), and an external confirmation button (pins 6 and 37/47) is required to ensure that manual confirmation is necessary to restore automatic operation after the door is closed.

5.5 Startup Mode

The 'startup mode' allows temporary disabling of external protective devices in T1 state for debugging and troubleshooting purposes. After activation, all safety outputs must be forced to logic 0, and the danger zone must be isolated with warning tape. This mode is strictly prohibited for normal operation.

Chapter 6 Operation Mode and Safety Measures

6.1 Operating Mode

Mode description speed limit

T1 manual slow speed ≤ 250 mm/s, enable effective, safety door ineffective

T2 manual fast programming speed, enable effective, safety door ineffective

AUT automatic programming speed, safety door effective, unable to be manually operated

AUT EXT is automatically controlled by the upper level controller, and the safety door is effective

6.2 Stop Response

Stop categories corresponding to different triggering conditions:

Trigger conditions T1/T2 AUT/AUT EXT

Press the start button to release STOP 2-

Press the STOP button and hold down STOP 2

Drive to close STOP 1 STOP 1