KUKA KR C4 extended assembly and debugging

The control PC can be equipped with D3076-K, D3236-K, or D3445-K motherboards. D3076-K provides 7 fieldbus slots LAN Dual NIC、 4 USB 2.0, DVI-I, and LAN Onboard. D3236-K offers 7 fieldbus slots, 2 USB 3.0, DVI-I, 4 USB 2.0, and LAN Onboard. D3445-K offers 7 fieldbus slots, 2 USB 3.0, DVI-D, Display Port, 4 USB 2.0, and LAN Onboard. VGA can be achieved through an adapter, but external displays are only available when not connected to a smartPAD or virtual remote teaching pendant. The bus system includes KCB, KSB, and KEB. KCB connects KPP, KSP, RDC, CIB, and EMD; KSB connects CIB, SION, smartPAD, and SIB; KEB can connect devices such as PROFIBUS, DeviceNet, digital/analog I/O, EtherCAT bridging, etc. EtherCAT slave can be connected via X44 on CIB or can be exported via optional X65. X66 is a KUKA Line Interface used for external computer connections. X69 is the KUKA service interface used for diagnosis and WorkVisual configuration.

Security Interface X11 and Ethernet Security

The X11 security interface is a 50 pin D-Sub connector, which is internally connected to SIB. In the default configuration, test outputs A and B provide pulse voltage, which is only used for the safety input of the corresponding channel and cannot be used as a regular power supply. External emergency stop channels A and B are dual channel inputs with a maximum voltage of 24 V. Operator safety channels A and B are used for the safety door locking mechanism. Confirm the operator's safety input for confirmation after the safety door is closed. Safe operation stop channels A and B are used for static monitoring. Safe stop 2 channels A and B are used to trigger stop 2 and static monitoring. External Enable 1 and 2 are used for external dual channel enable switches. The local emergency stop output is a floating contact that closes when the smartPAD emergency stop is not pressed and the controller is turned on and running. Confirm that the output can be used to safely forward the operator to other robot controllers on the same safety fence. Peri enabled output is set to 1 when the driver is turned on, the safety controller motion enable exists, and the "Operator Safety Open" message is not activated.

During dynamic testing, the test output is alternately turned off, with a turn off pulse length t1 of 625 μ s and a range of 125 μ s to 2.375 ms. The time t2 between two turn off pulses on the same channel is 106 ms, and the offset t3 between two turn off pulses on the same channel is 53 ms. The input channel SIN_X_A must be powered by TA_S, and SIN_X_B must be powered by TA-B. The safety output is a dual channel floating relay output, and the power supply must come from a safety isolated PELV power supply. When wiring, input signals and test signals, output signals and test signals must be separated to prevent cross connections. The wiring example can achieve category 3 and performance level d.

The Ethernet safety interface X66 supports PROFIsafe or CIP Safety. The input byte 0 contains reserved bits, external emergency stop, operator safety, confirmation, safety stop 1, and safety stop 2. Output byte 0 contains local emergency stop, drive enable, motion enable, enable signal, Peri enabled, AUT, T1 and T2 modes. It is recommended to preset the input to 1 to prevent unexpected activation of new security features after software updates, which may cause downtime. SafeOperation can be used through an Ethernet secure interface, with input bytes including mastering testing, slowing down, stopping secure operations, monitoring space, and tool selection; The output bytes include SO, RR, JF, VRED, SBH, and MR. In input byte 2, JR is the master test input, VRED is activated to reduce speed, and SBH1 to 6 are axis group safety operation stops. In output byte 2, SO represents the security option activation status, RR represents the robot has been referenced, and JF represents the mastering error. In output byte 3, SBH5 to 6 and SOS are used for safe operation stop status. The safety function complies with EN ISO 13849-1 Category 3 and Performance Level d, with a PFH value of less than 1 x 10 ^ -7.

PE equipotential and power connection

PE equipotential connection is a necessary task before assembly. Connect the robot motion system and robot controller using a 16 mm ² cable. Use a 16mm ² PE conductor to connect the central PE row of the power supply cabinet and the PE bolt of the controller. If a drive box is installed on the KR C4 extended, a 16 mm ² PE conductor needs to be connected between the drive box and the workshop equipotential. After installation, a fault circuit impedance test must be conducted in accordance with section 18.2.2 of EN 60204-1.

The power connection is completed through the X1 Harting connector. The control cabinet can only be connected to a power system with a grounded neutral point. The rated voltage can be selected from 3x380 V AC and 3x400 V AC, with a permissible deviation of ± 10%. The frequency is between 49 and 61 Hz, and the system impedance does not exceed 300 m Ω. The ground leakage current of KPP G1 can reach 300 mA, and KPP G1 and G11 can reach 600 mA. The short-circuit current rating is 25 kA at 480 V AC and 20 kA at 575 V AC. The main power supply is fused: a minimum of 3x25 A slow melting is required for KPP G1 only; Minimum 3x50 A slow melting for KPP G1 and G11. If using RCCB, attention should be paid to the residual current that may exist during fault free operation. RCCB is used for equipment protection rather than personnel protection, and it is recommended to use universal current sensitive and selective models. Before connecting the power supply, it is necessary to cut off the power, hang a tag, confirm that there is no power, and follow the five step safety rules.