KUKA KR CS Box-2 Compact Controller for Four Axis SCARA Robot

The operating modes include T1, T2, Auto, Remote, and Servo Free. T1 speed not exceeding 250 mm/s; T2 can exceed 250 mm/s; Auto is used for program execution; Remote executes commands through I/O; Servo Free allows operators to manually grasp the moving axis of the robotic arm. J1 and J2 brakes can be released through software, while J3 and J4 brakes can be released through the release button on the robotic arm. The priority of emergency stop related control equipment is the highest, including external emergency stop, teaching pendant emergency stop, and safety door sensor; Teaching pendant, control PC, confirmation button, enable switch, remote PLC, and Ethernet remote operation have lower priority. Whoever connects to the teaching pendant and controls the PC first gains exclusive control.

Interfaces and wiring: Emergency, I/O, EtherCAT, LAN, and USB

The Emergency interface is 25 pins and includes system automatic mode indication, safety door status indication, emergency stop status indication, external enable test pulse, safety sensor test pulse, confirm button output, external emergency stop test pulse, external enable input, safety sensor input, confirm button input, and external emergency stop input. Safety related outputs can be connected to indicator lights or LEDs, requiring external 24V power supply and a load not exceeding 100 mA. Shielded cables must be used for safety circuits, with a recommended wire diameter of AWG 22, and measures must be taken to prevent cross connections between channels.

The EtherCAT interface uses RJ45, with pins defined as 1 TX+, 2 TX -, 3 RX+, 6 RX -, and 8 PE. The maximum wire diameter is AWG 22, and Cat5 shielded cables are recommended. The LAN interface provides a 100 Mbps service channel for KUKA. ControlStudio on PC, and Cat5 shielded cables are also recommended. The USB Memory interface is USB 2.0 Type A, used for data backup and recovery, and is used in conjunction with the Trigger button. The I/O interface is 50 pins, providing 24 digital inputs and 16 digital outputs. The input voltage range is DC 20.4 V to 26.4 V, the input impedance is 5.4 k Ω, and the typical operating current is 4.2 mA. The output is a solid-state relay, with NPN from 0 to 7 and PNP from 8 to 15. The operating voltage is DC 20.4 V to 30 V, with a maximum single point of 200 mA. The input common terminal can be connected to 0 V or 24 V, and NPN or PNP connections are supported. When connecting the output to a relay or inductive load, a freewheeling diode must be added, otherwise it may damage the output. PE protection equipotential connection requires the use of a 4 mm ² cable to connect the robotic arm and controller, and connect them to the central PE row along the shortest path. Finally, perform grounding inspection according to EN 60204-1.

Installation, power on, and initial debugging

The dimensions of KR CS Box-2 are approximately 280 mm × 310 mm × 120 mm, with a minimum spacing requirement of front 100 mm, back 60 mm, left 60 mm, and right 60 mm to ensure heat dissipation. The controller can be placed horizontally or installed vertically through a bracket. When installing vertically, first remove the 4 M3 TORX feet, then install the bracket and use 4 M4 × 8 self tapping internal TORX screws with a tightening torque of 1.7 to 1.8 Nm. The power supply must use a grounded neutral system for independent protection, and it is recommended to use a 16 A, 30 mA B-type residual current protector for each robot; When multiple robots share the same total protection, it is recommended that the total remaining operating current for 1 to 7 robots be no less than 100 mA and the rated current be no less than 32 A; for 7 to 25 robots, it is recommended to be no less than 300 mA and 100 A; It is recommended to use no less than 500 mA and 160 A for 25 to 40 units. Before powering on, confirm that there is no condensation, all connections are correct, the casing is closed, and there is no one in the danger zone. Release the teach pendant emergency stop, turn on the main switch, log in with the default username admin and password ADMIN after system startup, and then change the default password. If the teaching pendant is not used, a bypass connector must be inserted into the TP interface to simulate emergency stop not being pressed and enable disconnection, and the teaching pendant must be removed to prevent the mistaken belief that its emergency stop is still valid.

Maintenance: Wait for 10 minutes, clean the filter and ventilation holes

Before maintenance, the controller must be turned off and locked with a tag, the power cable must be unplugged, and wait for at least 10 minutes, as there may be residual voltage of 60 to 450 V in the intermediate circuit. Clean the filter screen every 3 months, clean the ventilation holes every 12 months, and conduct cyclic functional tests on all safety equipment and emergency stop devices annually. Check if the fuses, plugs, and boards are securely fastened, and inspect the potential of cables, PE, and system components for wear or damage. During cleaning, it is prohibited to use compressed air, spray water, use solvent-free, water-soluble, non flammable, and non corrosive cleaning agents, and do not allow cleaning agents to enter electrical components.