KUKA KR C5 micro debugging and troubleshooting

In terms of 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. 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.

The safety rule set includes Operator Devices (emergency stop, enable), Velocity Monitoring (T1/CRR maximum 250 mm/s, manual guidance default 500 mm/s or 900 mm/s, global maximum 2000 mm/s default disabled), Standard Safety Interface (safety door, external emergency stop), HRC (transient contact) (collision detection 30 Nm, speed 500 mm/s). The operation safety signal is used to monitor physical protection such as safety doors. In automatic mode, it can only move when the operation safety signal is set or the robot is manually guided. Operation safety is not activated by default in T1 and CRR modes, and signals are not evaluated. If there is no physical protection, the collaborative operation requirements of EN ISO 10218 must be met.

Interface layout and wiring

The interfaces of KR C5 micro are concentrated on the front and rear panels. The front panel 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 connection; 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 motor interfaces of 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 connection interface XD1, and interface XD2 for UPS 24V power supply and daisy chain connection. XD1 pins are L1, N, and PE. The power connection uses the inlet C15 of the 3-pole high-temperature appliance, and the equipment within the supply scope must be connected with cables or main power connectors. Single phase power supply is AC 200 to 240 V ± 10%, single-phase TN system or single-phase three wire system; Two phase power supply is 208 Y/120 V or 240 Y/131 V, solidly grounded wye, three-phase four wire, must be connected to two phases, ensuring that the power supply voltage is within the range of 200 to 240 V ± 10%, and the two phases are as symmetrical as possible. Device side fuse 2 × 10A slow melting C-type.

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 fuse of 10 A.

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 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 terminal, update services, diagnostics, with a maximum cable length of 100 m. The KEI interface is used to connect external EtherCAT slave stations. 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 motor interfaces XD20.1 and XD20.2 have the same design, but are distinguished by different non interchangeable codes (Type A and Type B). XD20.1 connects M1 to M3, XD20.2 connects M4 to M6. The brake interface is also integrated into it. 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.

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.