KUKA KR C5 micro With KUKA System Software (KSS/VSS) Assembly Instructions

KR C5 micro (running KSS/VSS library card standard system software, different from iiQKA.OS version), compatible with smartPAD-2 teaching pendant; The protection level of the controller body is IP20, and it must be installed in a protective cabinet before it can be used on industrial sites; Supports up to 6 servo axes and can be paired with an L3EA external axis drive box to expand up to 2 external servo axes. For engineering personnel with a background in electrical and Windows systems, it is recommended to complete KUKA College training.

Product Description

Whole machine composition: robotic arm body+KR C5 micro controller+smartPAD-2+cables+KSS/VSS software+options.

Hardware composition

Control Unit Control Box

Mini CSP panel: Mode LED, Run LED, Fault LED, Soft Power button;

SYBperf performance system motherboard, microSD card (storage controller configuration), SSD hard drive;

IFBstd standard IO board (standalone version)/IFB-TCA-OUT adapter board (cabinet 4CAB version).

Drive Unit Drive Box (KSP-300/KSP-300-4)

FCU-300 power supply unit, SCU-6-1S safety control unit;

Fan, filter, braking resistor; Generate an intermediate DC bus, control the motor and brake, and strictly prohibit unauthorized disassembly of the power unit housing, as there may be fatal high voltage.

Interface Overview

Ethernet group XF1-XF8

XF1 KSI service port (WorkVisual debugging, access to enterprise LAN prohibited);

XF2 KLI-IT (IT Network, Backup OPC‑UA）；

XF3/XF4 Daisy Chain Multi Controller Cascade (RoboTeam);

XF5-XF6 KLI-OT (OT fieldbus PROFINET/EtherNet IP);

XF7 KONI option network port; XF8 KEI EtherCAT (supports FSoE Ethernet security).

Security Interface

XG11.1: 2-channel secure input, 1-channel secure output; Used for external emergency stop and safety doors; Dual channel TA-A/TA-B dynamic pulse detection;

XG58: 2-channel secure input; Used for external three position enable switch and additional local emergency stop;

​If Ethernet safety (PROFIsafe/CIP Safety/FSoE) is enabled, XG11.1 and XG58 discrete safety inputs will no longer be evaluated by the controller, and either option will be used.

Other key interfaces

XG19: smartPAD-2 teaching pendant;

XF21: RDC rotary digital converter (mechanical arm position, temperature acquisition);

XG33: Fast measurement input+”Drives ready” indicator light output;

XG12:16 input/16 output non safety IO, can switch high/low side according to a set of 8-channel jumpers;

XD1: Single phase AC main power input;

XD2:24   V UPS interface (power off controlled shutdown; supports multi controller daisy chain cascade power supply, without UPS operation, position/configuration data will be lost);

XD20.1/XD20.2: Two sets of motor connectors, driving A1-A3 and A4-A6 axis motors and brake respectively, with connector codes to prevent incorrect insertion.

Cooling and installation form

Dual fan air cooling; Bottom inlet air, rear outlet air; Air ducts must not be blocked;

Supports multiple installations: horizontal placement, side wall vertical placement, stacking up to 3 controllers, wall mounted, 19 inch rack installation;

Misuse List: Prohibited for use on platforms, outdoors, explosion-proof, radioactive, and underground mining. Misuse will result in the loss of all warranty.

Security Chapter

The controller belongs to partially completed machinery and cannot be directly put into production; The system integrator completes the risk assessment and issues an EC compliance statement; Safety level EN ISO 13849-1 Cat.3/PL d, PFH<1 × 10 ⁻⁷, 20-year design life; The emergency stop and enable switches must undergo functional testing every 12 months.

1) Stop category (EN60204-1)

STOP 0: Immediately cut off the power supply to the drive and brake;

STOP1: Controlled deceleration shutdown, cutting off the drive after shutdown;

STOP2: Keep the drive powered on and perform static monitoring.

2) Personnel Definition

Distinguish between users, system integrators, operators/debuggers/maintainers/cleaners; Only specially trained personnel are allowed to install and debug hardware.

3) Regional definition

Workplace: Robot motion range; Dangerous zone=workspace+robotic arm+external axis stopping distance;

Stop distance test conditions: The robot is equipped with actual tools and loads, and runs for about 1 hour to reach working temperature. STOP0/STO1 is tested multiple times and the worst value is taken.

4) Operation mode

KSS software mode

Mode Usage Speed Limit

T1 manual deceleration teaching debugging TCP maximum 250 mm/s, overspeed triggers STOP0, must be held down to enable the middle position

T2 manual high-speed test>250 mm/s, prohibit teaching programming

AUT standalone automatic mode program setting speed

AUT-EXT upper PLC external automatic mode program setting speed

VSS Mass Version Software Mode

T1, T2, EXT external automatic; T1 can use E2/E22 bypass safety doors; T2 uses E2/E22+E7 bypass safety doors.

5) Core security functions

Emergency stop

Local emergency stop: smartPAD-2 emergency stop; Unplug the teaching pendant and the emergency stop will fail; The system must be additionally configured with an external emergency stop; Press to execute STOP1.

Three position enabling device: SmartPAD-2 has four three position enabling devices; Release → STOP2; Completely press the panic button → STOP1; Support XG58 external enablement.

Operator safety (safety door): AUT/AUT-EXT mode is activated; Opening the safety door triggers STOP1; Prohibit automatic reset of door closing, external confirmation button is required.

T1 mode speed monitoring: The rotation axis defaults to 30 °/s, Cartesian TCP defaults to 250 mm/s, and overspeed directly triggers STOP0.

Additional protection: software limit, mechanical hard limit; Manual release of the brake without driving energy (limited to personnel rescue only, may damage the motor brake).

Startup mode: In T1 mode, external security protection can be bypassed for fences that have not yet been installed and debugged; The hazardous area must be physically isolated and used as little as possible.

SPOC single point control security: Submit, PLC, OPC UA, remote tool access robot; In T1/T2 mode, $USER_SAF=TRUE and $SPOC_MOTION-ENABLE=TRUE are required, and rewriting motion related variables such as speed and magnification is prohibited in the background.

6) Key points for homework safety

After a power outage, the maximum voltage in the intermediate circuit is 800 VDC. Maintenance must disconnect the power cord and wait for at least 5 minutes for discharge; Strictly implement the 5-step method for electrical safety; ESD anti-static throughout the process.

New programs/modified programs must prioritize T1 mode testing; To simulate downloading a physical machine, T1 verification is required.

Maintenance and repair must be powered off, locked, and tagged; Live operation is limited to T1 mode only, emergency stop must remain available.

IT security: controllers are included in enterprise information security management; KSI service port prohibits access to enterprise LAN.

7) Reference standards

Machinery Directive 2006/42/EU, EMC Directive 2014/30/EU, EN ISO 13849-1/2, ISO 10218-1, EN 60204-1, etc.

Technical Data

Basic Electrical

Maximum servo axis: body 6 axes; Up to 2 external shafts can be paired with an additional drive box;

Weight approximately 9.8kg; IP20 (module body, must be installed in a cabinet for on-site protection); Noise level<54 dB (A);

Power supply: single-phase AC 200-240   V ± 10%, 50-60Hz; also supports two-phase grounded star grid connection; Apparent power of 1.30 kVA; Leakage current ≤ 10   mA; equipment side fuse 2 × 10   A slow melting C-type.

Environment: Operating at -5~+45 ℃; Storage -20~+60 ℃, no condensation;

Altitude: ≤ 2000 meters without power reduction; Reduce capacity by 5% for every 1000 meters between 2000-3000 meters;

Vibration impact: Running continuously for 3   g, with an impact of 10   g (11ms half sine).

Safety IO electrical parameters

Safe output: ≤ 30   V; current 10-500   mA; maximum cable length of 50   m; maximum 20-year lifespan of 9.5 million switching cycles, module replacement upon expiration;

Safe input: 5-11V is an undefined transition zone; ≤ 5   V disconnection, ≥ 11   V conduction; Dual channel TA-A/TA-B 600 µ s alternating pulse fault detection.

Mechanical and installation clearance

Body size: 300  × 410  × 137   mm; with stress relief plate depth of 513   mm;

Independent placement: minimum 100   mm for air inlet and minimum 100   mm for air outlet;

Install into protective cabinet (≥ IP54): The distance between the front (inlet) of the controller and the inner wall of the cabinet is ≥ 150mm; the distance between the rear outlet and the inner wall of the cabinet is ≥ 100mm;

Stacking up to 3 units; When stacking, the lower controller must be fixed to the ground;

REACH regulation SVHC high concern substance information access KUKA Xpert; The nameplate warning label is strictly prohibited from being torn off.

System Planning

EMC electromagnetic compatibility: EN55011 Class A Group 1 industrial equipment; All external communication cables use shielded cables, and the shielding layer is extensively grounded.

Installation requirements

Can be independently placed, wall mounted, stacked, 19 inch rack; The bottom of the wall mounted installation is the air inlet, which must be protected against dripping water;

In environments with conductive dust and condensation, the controller must be installed in a protective cabinet with at least IP54 rating.

PE equipotential grounding

Manipulator ↔ Controller: 4mm ² copper wire;

The controller is connected to the main PE busbar in the factory area, and it is recommended to use 4mm ² copper wire; Both the front and rear shells of the controller have PE terminals.

Cable laying

Fixed wiring bending radius ≥ 3-5 times the outer diameter of the cable; Within the drag chain, ≥ 7-10 times;

Separate the wiring of motor power cables and signal data cables;

The maximum length of the entire robotic arm cable is 25 meters; if the XF21 RDC/TPC data cable is replaced, all axes must be recalibrated for mastering.

Power supply: must be TN grounded neutral grid; Suggest using a B-type selective 30mA leakage protector.

Detailed interface description

XG58: External three position enable+additional local emergency stop; Short circuiting of jumper wires at the factory; The external enable switch must use the specified model 0000-358-565 from the KUKA;

XG11.1: Dual channel safety input (external emergency stop, safety door)+one safety output; Dynamic pulse TA-A/TA-B;

XD2 UPS: 24V input; Supports up to 3 controllers sharing a set of 24V UPS power supply; Distinguish between UP_SYNC/PSU_SND jumper modes (central 24V power supply/battery power supply);

XG12 ordinary IO: switch high/low side mode by using a set of jumper wires with 8 channels;

XF8 KEI EtherCAT: Supports FSoE security protocol; After enabling Ethernet security, XG11.1/XG58 discrete security inputs are no longer evaluated.

Safety performance: PFH<1e-7; Satisfy Cat.3 PL d, with the prerequisite of conducting a complete set of safety function tests annually.

Transportation

Unplug all cables and close the cover plate; Horizontal placement of hand carts for transportation; Take measures to prevent falls and avoid impact and vibration;

Prohibit savage falls.

Startup and restart 

Complete startup process

Visual inspection of transportation damage; Confirm that there is no condensation inside;

Fix the controller in place and strictly follow the ventilation gap;

Connect the robotic arm to the controller’s PE equipotential, and connect the controller to the main PE protective ground;

Laying motor cables and XF21 robotic arm RDC data cables; Stress release of cables to eliminate pulling and pulling;

Connect smartPAD-2 to XG19;

Power off status wiring XG11.1 (external emergency stop, safety door), XG58 (external enable); Hot plugging is prohibited for secure interfaces;

XD1 connected to single-phase main power supply; XD2 connected to 24V UPS power supply;

Hardware modifications (such as replacing boards and hard drives) require WorkVisual to regenerate and download project configurations; Directly interchange hardware of the same model;

Enable Startup mode as needed; Confirm that there are no people in the danger zone and all safety measures are in place; Close the power switch of the device;

Startup sequence: Restore USB drive → External hard drive → Internal SSD; Identifying external hard drives will disable internal SSDs;

Software debugging: machine data verification, no-load calibration, load calibration, TCP tool calibration, load input, software limit setting, AUT-EXT external automatic interface configuration.

Operation

Soft power button: Short press to shut down normally; Press and hold for ≥ 5 seconds to force a hard power outage (avoid as much as possible, there is a risk of damaging the system);

Power off the entire machine: Disconnect the device switch and unplug the XD1 power cord.

Maintenance

Turn off the power and unplug the power cord, and force the intermediate circuit to discharge for at least 5 minutes; ESD anti-static throughout the process; Do not use compressed air or spray water for cleaning.

maintenance cycle

Every 12 months

Complete functional testing of all emergency stops and all enable switches (enable switch test: operating in T1 mode, fully press and hold the enable switch for 3 seconds, and the robot must stop immediately);

Drive ready indicator light function test;

Depending on the degree of dirt: clean the intake and exhaust grilles;

10 years: Replace the CR2032 button battery on the motherboard, and reset the BIOS date and time after replacement.

Repair

Only the manual describes that on-site maintenance is allowed for the project; Other repairs must be carried out by KUKA trained personnel; KUKA original spare parts must be used. On site replaceable components, unified pre safety conditions: power-off, unplugging power cord, waiting for 5 minutes for discharge, ESD protection:

Stress relief plate;

19 inch rack mounting frame;

SSD hard drive;

System motherboard button battery CR2032;

Rear input fuse F1/F2 (10A slow melting);

SYBperf system motherboard (standalone version/4CAB cabinet version);

IFBstd standard IO interface board;

IFB-TCA-OUT interface board;

KSP-STA external axis interface card.

Before replacing the motherboard/interface board, it is necessary to first remove the microSD card and SSD hard drive; Pay attention to wiring during disassembly and assembly to prevent breakage.

Troubleshooting 

KSP power unit alarm message; Mini CSP panel LED fault code; System motherboard hardware malfunction LED;

KR C5 Recovery Image: Complete steps for creating a recovery USB drive, importing a recovery image, and exiting the recovery environment.

Discontinuation, storage, and disposal

Retired shutdown: Power off, unplug all cables, and remove all external wiring;

Storage: Indoor dry and dust-proof, batteries stored separately; Seal the interface, dust cover+desiccant; Avoid condensation;

Scrap: Circuit boards are used as electronic hazardous waste; Button batteries should be recycled separately, and disposal of household waste is prohibited.