KUKA KR C5 micro KSS troubleshooting

T1 speed monitoring is divided into axis specific and Cartesian monitoring. Axis specific monitoring defaults to a rotation axis of 30 °/s and a linear axis of 250 mm/s. Exceeding the limit triggers a safety stop of 0. Descartes monitoring defaults to 250 mm/s, which can be configured using options such as SafeOperation, but can only be reduced and cannot be increased. The Drives ready light must be tested before entering the danger zone: press and hold the enable switch at T1, and the light should turn on; Press to the panic position, the light should turn off.

Interface Layout: Safety, Communication, and Power Supply

The KR C5 micro front panel interface includes: XFUSB1 and XFUSB2 for USB 3.0; XF1 to XF8 are Ethernet and EtherCAT interfaces, and the specific allocation depends on the system software; XGDP is DisplayPort DP 1.2; XGSD is used for microSD cards; XG19 is used for smartPAD; XD12 and XD12.1 are 24V power supplies; XG12 provides 16 digital inputs and 16 digital outputs; XD20.1 is used for motor interfaces of axes A1 to A3; XD20.2 is used for axes A4 to A6; XG33 provides 3 fast measurement inputs and 1 Drive ready light output; XF21 is used for RDC or TPC; XG58 is a secure interface; XG11.1 is a secure interface. The rear panel includes device switches, fuses F1 and F2, power connections XD1 and XD2 for UPS 24V power supply and daisy chain connection.

In XF1 to XF8, XF1 is the KSI service interface, XF2 is the KLI IT, XF3 and XF4 are daisy chains, XF5 and XF6 are the KLI OT, XF7 is KONI, and XF8 is KEI. The KSI interface is used for diagnosis, WorkVisual configuration, and updates, and must not be connected to IT networks with a maximum cable length of 100 m. The KLI interface can be connected to OT or IT networks for PLC, terminals, update services, and diagnostics with a maximum cable length of 100 m. The KEI interface is used to connect external EtherCAT slaves, and EtherCAT devices must be configured with WorkVisual. The maximum cable length for XGDP is 5 meters. The maximum cable length for the Drive ready light output of XG33 is 50 meters. The maximum cable length for the RDC/TPC connection of XF21 is 50 meters.

The security interface XG11.1 provides 2 security inputs and 1 security output. The default configuration is: security output 1 is for local emergency stop, security input 1 is for external emergency stop, and security input 2 is for operational safety. XG58 provides 2 safety inputs for external enable switches and additional emergency stops, as well as for reference switches. The secure input adopts a dual channel design with external testing and loop detection shutdown capability. The test outputs TA_S and TA_S are alternately turned off, with a turn off pulse length of 600 μ s, a single channel turn off period of less than 1 second, and a 50 ms offset between the two channels. The input channel N_A [x] must be powered by TA_S, and N_B [x] must be powered by TA_S, and no other power sources must be used. Only sensors that can access test signals and provide floating contacts are allowed to be connected.

XG12 digital I/O can be configured in high side or low side mode. Jumpers 1 to 2 switch inputs 1 to 8 to low side, jumpers 3 to 4 switch inputs 9 to 16 to low side, jumpers 5 to 6 switch outputs 1 to 8 to low side, and jumpers 7 to 8 switch outputs 9 to 16 to low side. Default high side. The power supply is provided through XD12 and must use a safely isolated PELV/SELV power supply, rated at 24 V ± 10%, with a maximum insurance of 10 A. XD2 is used for UPS, with a maximum of 6.5 A for the first 60 seconds after power failure, and a maximum of 4 A until complete shutdown; without UPS, the controller should not operate, otherwise data loss may occur. XD55.1 to XD55.4 provide a 27 V power supply on the external shaft drive box and are internally protected by a 3A fuse.

Installation, power on, and initial debugging

The KR C5 micro can be installed horizontally or vertically, with or without a bracket, stackable, can be installed in a 19 inch rack, wall mounted, or as a panel mounted variant. The minimum distance must be observed during installation: at least 150 mm between the front (air inlet) of the robot controller and the housing, and at least 100 mm between the rear (air outlet) and the housing. If wall mounted, additional fire protection measures must be taken and can only be used or equipped with drip protection inside the fireproof housing. The front and rear must always be able to come into contact with cooling air. Stacking up to 3 controllers, the lower controller should be fixed on the ground, and the upper controller should be installed diagonally using 4 brackets. 19 inch rack installation requires the use of an installation frame with a minimum insertion depth of 700 mm. When installing the bracket, M5 screws are used for horizontal installation and M6 screws are used for vertical installation.

The equipotential connection must be completed before power on: a 4 mm ² cable is used between the robotic arm and the controller; An additional PE conductor of 4 mm ² is recommended to be used between the central PE row of the power supply cabinet and the PE connection of the controller. The connecting cable must be laid separately from the data cable, with a fixed installation bending radius of 3 to 5 times the cable diameter, and a drag chain installation radius of 7 to 10 times. The length of motor cables and data cables between the controller and the robot must not exceed 25 meters. After replacing the data cables, it is necessary to re master or perform master tests on all axes.