KUKA KR C5 micro KSS troubleshooting

KUKA KR C5 micro KSS troubleshooting

KUKA KR C5 micro is a controller platform designed for small robots, compact workstations, and limited installation spaces. When equipped with KUKA System Software (KSS) or VW System Software (VSS), it supports up to 6 servo axes, weighs approximately 9.8 kg, has a protection level of IP20, noise level below 54 dB (A), power supply from AC 1 × 200 V to 240 V, allowable deviation ± 10%, rated connection power of 1.30 kVA, main power side fuse 1 × 16 A slow melting C-type, and maximum thermal output of 250 W. Unlike the iiQKA.OS version, the KSS/VSS version uses KUKA smartPAD-2, with its own operating mode, safety rules, and fault diagnosis path. The on-site engineers are most concerned about how to distinguish between the control box and the drive box, how to configure the safety chain, how to wire the interface, how to verify the first power on, how to replace the module, and how to quickly locate the KSP alarm and CSP LED. This article revolves around these practical issues.

System Architecture: Control Box, Drive Box, and Cooling

The KR C5 micro consists of a control unit and a power unit. The control unit, also known as the control box, contains a mini CSP, button battery, SSD hard drive, system board, IFBstd interface board, internal SSD storage, and fan. The system board is responsible for controlling the computer, including graphical interfaces, program creation and modification, path planning, sequence control, drive loop control, monitoring, safety equipment communication, and external device communication. The IFBstd interface board provides non secure digital I/O and is connected to the system board through a ribbon cable; The system board is connected to KSP through ICT plug and is powered by KSP. Mini CSP is a status display component that provides feedback on operating mode, operating status, errors, and sleep status through LED1 to LED4 and a soft power button.

The drive box, also known as the drive box, includes a fan, main filter, braking resistor, radiator, and KSP-300 drive controller. KSP-300 consists of FCU-300 and SCU-6-1S, used for up to 6 servo axes; KSP-300-4 consists of FCU-300-4 and SCU-6-1S and is used for up to 4 servo axes. The drive box is responsible for generating intermediate circuit voltage and system voltage, controlling the motor, controlling the brake, and checking the intermediate circuit voltage in braking mode. The power unit is not allowed to be opened arbitrarily, otherwise it may cause serious injury or property damage. The KR C5 micro also supports the Customer Kinematics variant, which can use KUKA motors to control non KUKA industrial robots. Cooling is achieved by two fans, with air entering through the inlet and exiting through the outlet. The front and rear surfaces must be kept in contact with the cooling air.

Safety Chain: STOP 0/1/2, Operational Safety and Enabling Devices

The safety features of KR C5 micro comply with Category 3 and Performance Level d of EN ISO 13849-1. The premise is that each emergency stop device should be pressed at least once every 12 months, each enabling device should be checked at least once every 12 months, and the USS 2 peripheral contactor should also be tested regularly. Safe stop is divided into STOP 0, STOP 1, and STOP 2. STOP 0 immediately cuts off the drive and applies the brake, and the robot stops in a path guided manner. STOP 1 is executed by the non safety part for braking, monitored by the safety controller. At T1, the braking power is cut off after all axes come to a standstill or at the latest 680 ms, and the drive is cut off after 200 ms; Under T2, AUT, and AUT EXT, the drive is cut off by default after 1.5 seconds, and the brake power is cut off 200 ms in advance. STOP 1 DRS is used for safety options with BBRA. After braking, the brake power is cut off according to the configured time plus 500 ms oscillation time. STOP 2 does not cut off the drive, does not apply the brake, and maintains a braking ramp deceleration path.

The operating modes of KSS are T1, T2, AUT, AUT EXT; VSS is T1, T2, EXT. T1 is used for testing, programming, and teaching, with a maximum program validation speed of 250 mm/s and a maximum jog speed of 250 mm/s. T2 is used for testing, and the program verification speed is set according to the program settings. Jogging is not available. AUT and AUT EXT are used for program execution and jogging is not available. The operation safety signal is used to monitor physical protection such as safety doors. Without this signal, it cannot operate in automatic mode; Opening the safety door during operation will trigger safety stop 1. Operation safety is not activated under T1 and T2. Under VSS, T1 can be operated safely with E2/E22 key bypass, T2 can be operated with E2/E22+E7 bypass, but no one is allowed in the danger zone under T2.

The emergency stop device includes local emergency stop and external emergency stop on smartPAD. Pressing the smartPAD emergency stop will trigger safety stop 1, which must be rotated and released before it can be restored. The system must have at least one external emergency stop so that it can still be stopped when the smartPAD is disconnected. The enabling device consists of four enabling switches on the smartPAD-2, with three positions: not pressed, middle position, and fully pressed. Under T1/T2, only the middle position can move the axis; Release all intermediate position enable switches to trigger safety stop 2, and fully press one enable switch to trigger safety stop 1. The enable switch must not be fixed with tape and must undergo regular functional testing: move the robot in testing mode, press the enable switch to the panic position and hold it for 3 seconds. The robot must stop and no enable device errors must be displayed. The external enabling device is connected through XG58, with a maximum switching frequency of 20000 times, and must use the KUKA specified model.