KUKA Sunrise Cabinet Next Generation Small Control Cabinet

KUKA Sunrise Cabinet Next Generation Small Control Cabinet

KUKA Sunrise Cabinet is a robot controller launched by KUKA for industrial applications, mainly used to operate KUKA axes, including industrial robots and mobile platforms. It adopts a 19 inch chassis structure, weighs about 23 kg, has a protection level of IP20, and an average noise of about 54 dB (A). The power supply is 110 V/230 V AC single-phase, with an allowable deviation of ± 10%, frequency of 50 Hz ± 1 Hz or 60 Hz ± 1 Hz, rated power of about 1 kVA, heat dissipation of about 370 W, and recommended 2x15 A slow melting protection on the power supply side. The control cabinet must be connected to a power system with a grounded neutral point. The operating environment temperature ranges from 5 ° C to 45 ° C, and the storage and transportation temperature ranges from -25 ° C to 40 ° C. Without a battery, the storage and transportation temperature can be extended to -25 ° C to 70 ° C. No derating is required below an altitude of 1000 meters, and a derating of 5%/1000 meters is required below 3000 meters. The controller can be installed in a 19 inch rack with a depth of at least 600 mm, and a 70 mm cooling air gap must be left on both sides to prevent deformation and overheating of the casing. For on-site engineers, mastering their architecture, safety interfaces, maintenance cycles, LED diagnostics, fuse specifications, and component replacement processes is key to reducing downtime.

System architecture and key components

The core of KUKA Sunrise Cabinet consists of a control PC, CCU_SR, low-voltage power supply, battery, main filter, fan, interface, and connection panel. The control PC is responsible for graphic interface, program creation and maintenance, sequence control, path planning, drive circuit control, monitoring, safety equipment, and external communication. The control PC can use D3076-K, D3236-K, or D3445-K motherboards. D3076-K provides fieldbus slots, USB 2.0, DVI-I, and LAN Onboard interfaces; D3236-K provides fieldbus slots, USB 3.0/2.0, DVI-I, and LAN Onboard; D3445-K provides fieldbus slots, USB, DVI-D, Display Port, and LAN Onboard. Control PCs are typically equipped with quad core processors, at least 2 GB of memory, and SSD hard drives.

CCU_SR stands for Small Robot Cabinet Control Unit, which is the central power distribution and communication interface composed of CIB_SR and PMB_SR. It is responsible for safety input and output, contactor activation, 3 floating outputs, 7 safety inputs, identification of teaching pendant insertion, monitoring of fan power supply, and temperature detection inside the control box. Connect the Power Drive System through the KUKA controller bus; Connect the KUKA operation panel interface, diagnostic LED, and EDS interface through the KUKA system bus. The power supply with battery backup includes smartPAD, control PC quad core processor, and Power Drive System; The power supply without battery backup includes motor brake and customer interface. The low-voltage power supply supplies power to the control cabinet components and provides 48 V DC for the mechanical arm drive, with two green LEDs indicating the working status. The battery maintains a controlled shutdown in case of power failure or shutdown, charges through CCU_SR, and checks the battery level.

In terms of interfaces, the standard configuration includes X11 security interface, X19 smartPAD interface, X65 expansion interface, X69 service interface, X650 media flange interface, X21 robotic arm interface, X66 KUKA Line Interface, K1 power connection, and PE connection. X65 is used to connect external EtherCAT slaves; X66 is used to connect external computers for installation, programming, debugging, and diagnosis; X69 is used for diagnosing, configuring, and updating service laptops through KSI; X650 is used to power the external media flange of LBR iiwa wrist. The cooling system is completed by two fans, with air entering from both sides and exiting from the rear. Do not install filter cotton upstream of the ventilation duct, otherwise it will cause temperature rise and shorten equipment life.

Security features and X11 interface

The safety guidance function of KUKA Sunrise Cabinet complies with EN ISO 13849-1 Category 3 and Performance Level d, as well as EN 62061 SIL 2. The safety oriented function is used to protect personnel and must be tested at least once a year, unless otherwise specified in the workplace risk assessment. The test objects include local emergency stop devices, teaching pendant enabling devices, manual guidance enabling devices, external enabling devices, smartPAD key switches, and safety guidance outputs of discrete safety interfaces. The non safety oriented function is used to protect the machine, including mode selection, T1 speed monitoring, and software limit switches. The speed monitoring limit in T1 mode is 250 mm/s, and 250 mm/s is also pre configured for manual guidance, but can be adjusted based on risk assessment. The software limit switch is only used for machine protection, and stops under servo control when the axis exceeds the limit.

The safety stop categories include Stop 0, Stop 1, and Stop 1 (path preservation). Stop 0: Immediately disconnect the drive and apply the brake; Stop 1: Brake in a path keeping manner, disconnect the drive and apply the brake after stopping; Stop 1 (path maintenance) is triggered and monitored by the safety controller, and the brake should be applied and the drive disconnected no later than 1 second later. After the emergency stop device is pressed, the robotic arm stops with safe stop 1 (path maintenance). Enable the switch to release or press to the bottom, triggering safety stop 1 (path maintenance). The operator safety signal is used to monitor the safety door and is valid by default in T2 and automatic modes. Loss of signal triggers safety stop 1 (path maintenance). Before restoring automatic operation, it must be confirmed through an external confirmation button, and cannot be restored solely by closing the safety door. The external emergency stop device is connected through a secure interface and triggers secure stop 1 (path maintenance). External security stop 1 (path hold) is triggered through a security interface input. When the signal is False, it remains stopped, and when it is True, it can be moved without confirmation. External enabling devices are used for multiple people entering hazardous areas or manual guidance, where the robot can only move at a reduced speed during manual guidance. The external safety operation stop is a static monitoring function that does not stop movement, only monitors whether the axis is stationary.

The X11 security interface is a 50 pin D-Sub connector, which is internally connected to CCU_SR. In the default configuration, safety input 1 is external emergency stop, safety input 2 is operator safety, safety inputs 3 and 4 are safety stop 1, safety output 12 is local emergency stop, output 13 is test mode, and output 14 is automatic mode. 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. 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 SIL2 and Cat. 3.

Maintenance cycle and inspection

The maintenance work of KUKA Sunrise Cabinet should be carried out on a periodic basis. Check annually whether the relay outputs used by CCU_SR are normal. Default output 12 is local emergency stop, output 13 is test mode, and output 14 is automatic mode; After triggering the corresponding function, if there is no error message, it indicates that the relay output is normal. Clean the fan protective grille and fan at least annually based on installation conditions and pollution levels. Replace the motherboard battery every 5 years; Replace the fan every 5 years under 3 operating conditions. The battery replacement cycle depends on the battery monitoring indication. After maintenance, visually inspect the fuses, contactors, plugs, and boards for secure installation, no damage to cables, reliable PE equipotential connections, and no wear or damage to system components.

When cleaning the control cabinet, it is necessary to turn off the power and prevent accidental restarts, disconnect the power cable, and comply with ESD regulations. Wipe the casing with a mild cleaner and clean the cables, plastic parts, and hoses with a solvent-free cleaner. Do not use compressed air, do not spray water, and do not allow cleaning agents to enter electrical components. Replace damaged or unreadable labels and nameplates after cleaning. The battery should be charged every 9 months when the storage temperature is not higher than+20 ° C, every 6 months when the temperature is between+20 ° C and+30 ° C, and every 3 months when the temperature is between+30 ° C and+40 ° C to prevent deep discharge damage.

CCU_SR LED diagnosis

The LED on CCU_SR is the first-hand information for fault diagnosis. PHY4 and SW-P0 are green, constantly on or flashing indicates normal, and off indicates a fault. Usually, CCU_SR needs to be replaced. RUNSION EtherCAT safety node is green, off indicates initialization, constantly on indicates normal operation, flashing at 2.5 Hz indicates Pre Op, single signal indicates Safe Op, flashing at 10 Hz indicates firmware update boot. L/A green or orange indicates physical connection and data traffic: green constantly on indicates physical connection, off indicates no connection, flashing indicates data traffic; Orange represents 1 Gbit, green represents 100 Mbit. PWR/3.3 V, PWR/2.5 V, and PWR/1.2 V are green power indicators. When turned off, check the F17.3, X308 jumper plugs, F308, and external 24V power supply; If PWR/3.3 V is on and PWRS/3.3 V is off, consider replacing CCU_SR. When PWRS/3.3 V is turned off, check F17.3. If PWR/3.3 V is on, replace CCU_SR.

STAS2 and STAS1 are orange safety node indicator lights: check F17.3 when they are off, and replace CCU_SR if PWR/3.3 V is on; 1 Hz flicker is normal, 10 Hz flicker is the guiding phase; When the fault code flashes, check the X309, X310, and X312 cables. You can disconnect these cables and restart the controller. FSoE green indicates EtherCAT security protocol: off indicates inactive, constantly on indicates running, flashing indicates internal fault. KSB smartPAD_SC green/orange indicates smartPAD connection. RUN CIB_SR green indicates EtherCAT I/O node: normally on for running, off for initialization, flashing at 2.5 Hz for Pre Op, single signal for Safe Op, flashing at 10 Hz for firmware update. STA1 is an orange microcontroller I/O node: check F17.3 when turned off, and replace CCU_SR if PWR/3.3 V is on; 1 Hz flashing is normal, 10 Hz flashing guides, flashing is a fault code. STA2 is an FPGA node: check the X1 incoming line when it is turned off, and replace CCU_SR if PWR/3.3 V is on. 27 V, PS1, PS2 are green power indicators: when 27 V is turned off, check whether X1 is at 27.1 V; when PS1 is turned off, check whether X1 or the drive bus is at BusPowerOff; Turn off PS2 and check if X1 or controller is in Sleep state.

Fuses and Low Voltage Power Supply

When the CCU_SR fuse is damaged, the red LED next to it lights up. The replacement must use the same specifications. F306 is a smartPAD power supply, 2 A; F302 is unused, 5 A; F3-1 is unused, 15 A; F5-1 is unused, 15 A; F4-1 is a KPC with battery backup, 10 A; F307 is unused, 2 A; F4-2 is unused, 2 A; F22 is unused, 7.5 A; F5-2 is unused, 7.5 A; F3-2 is unused, 7.5 A; F17-2 is CCU_SR input, 2 A; F17-4 is CCU_SR safety input and relay, 2 A; F17-1 is CCU_SR contactor output 1 to 4, 5 A; F17-3 is CCU_SR logic, 2 A; F14 is unused Used, 7.5 A; F6 is 24 V with optional backup without battery, 7.5 A; F21 is PDS power supply, 3 A; F305 is battery fed, 15 A; F301 is backup without battery, 10 A; F15 is power fan, 2 A; F308 is external power supply, 7.5 A. Low voltage power supply unit fuse F1 is blown at 80 V, 5 A; F2 is blown at 80 V, 7.5 A. When troubleshooting, first check the fuse LED, Measure the voltage again and finally consider module replacement.

Common troubleshooting ideas

When there is no display when powered on, first check the power connection, main switch, X1 incoming line, and fuse to confirm whether the control PC is started. When the emergency stop cannot be reset, check whether the smartPAD emergency stop is released, whether the X11 external emergency stop circuit is closed, and whether the safety interface configuration is correct. When the operator's safety alarm is triggered, check whether the safety door is closed, whether the confirmation button is pressed, and whether X11 safety input 2 is normal. When the drive cannot be enabled, check the enable switch, external enable, safety stop 1 input, safety output, and CCU_SR LED. When the fan or temperature alarm occurs, clean the fan and heat sink, check the ambient temperature, and confirm that the ventilation duct is not blocked by filter cotton. When the battery alarm occurs, check the battery voltage and charging status, charge according to the storage temperature cycle, and replace the battery pack if necessary. When there is a communication failure, check the X65 EtherCAT, X66 KLI, X69 service interface, and motherboard LAN interface to confirm that the WorkVisual configuration is correct. When there is a safety output failure, check the PELV power supply, dual channel relay output, and external cross connections. Before any repair, the power must be cut off, labeled, and the voltage must be lowered to below 60 V, and ESD regulations must be followed.

Component replacement process

When replacing the motherboard, first turn off the controller and prevent restarting, disconnect the power, open the casing, unplug the fan connection, remove the fan bracket, remove the PC card, disconnect the motherboard connection, remove the Torx fixing screws, and place the motherboard on the ESD pad. After installing the new motherboard, restore all connections, fan racks, fan connections, and PC cards, and close the casing. When replacing the motherboard battery, open the casing, unlock the button battery locking mechanism, remove the old battery, insert the new battery, and lock it. When replacing the hard drive, open the casing, disconnect the power and data cables of the hard drive, remove the fixing screws, replace the hard drive with a new one, restore the connection and fix it. When replacing the battery pack, open the casing, loosen the Velcro strap, unplug the battery connection wire. Both battery blocks must be replaced at the same time, paying attention to polarity. G3.2 and G3.1 correspond to the positive and negative poles. Reinstall the Velcro strap and restore the connection. When replacing the fan, open the casing, remove the fixing screws of the fan bracket, unplug the fan connection, remove the inner and outer grilles, install the new fan, reinstall the fan bracket and connect it. Start the controller after replacement and observe for any abnormalities.