KUKA  KR C4 extended; KR C4 extended CK Assembly Instructions Assembly Manual

MA series=Assembly Instructions Assembly Manual, focusing on hardware planning, installation, wiring, pin definition, and power on debugging; Excluding component disassembly and repair, troubleshooting of faulty LED (this section is in the corresponding BA operation manual). KR C4 extended is a high-power multi axis control cabinet for KUKA, supporting up to 16 axes. It supports CK customer customized kinematics and is suitable for external axis projects of heavy-duty Titan robots, palletizers, and multi position machines. It is aimed at system integration engineers with professional backgrounds in electrical, robotics, and Windows.

Product Description

Complete system: robotic arm+KR C4 extended control cabinet+smartPAD teaching pendant+cables+KSS software+options.

Core Hardware

KPC Control PC: Mainboard D3076-K/D3236-K/D3445-K; Responsible for human-machine interface, program processing, path planning, driver control, communication, and security monitoring.

KPP KUKA power pack: Rectify AC power and output DC intermediate circuit voltage to supply power to servo units, integrating brake chopper; Provide multiple power versions, with panel LED running status indication.

KSP KUKA servo package: servo driver, multi peak current specification, performs motor field oriented torque control.

CCU cabinet control unit (CIB+PMB): complete power distribution, internal bus communication, safety IO, fan temperature monitoring, main contactor control, Mastering origin testing; Power outage relies on backup battery to store location and controlled shutdown.

SIB Security Interface Board (Standard SIB/Extended SIB Expansion Board)

Standard SIB: 5 safety inputs, 3 floating safety relay outputs.

Extended SIB: 8 secure inputs, 8 secure outputs; Used for SafeRobot and SRM axis interval monitoring, it must be used in conjunction with standard SIB.

RDC rotary transformer digital converter: collects up to 8 axis motor rotary transformer positions and motor temperatures; EDS memory storage origin configuration; Support cascading multiple RDC boxes to achieve up to 16 axis systems; The length difference of cables in each channel of RDC is ≤ 10 meters.

CSP controller system panel: running, sleep, automatic, and fault LED indicator lights; USB, KLI upper communication port, KSI service debugging network port.

Low voltage power supply unit, backup battery pack, power filter.

Three major bus systems

KCB controller bus: KPP, KSP, RDC, CIB;

KSB safety bus: SIB, SION safety nodes smartPAD；

KEB Expansion Bus: EtherCAT, Profibus, DeviceNet, Digital/Analog IO Expansion Modules.

Important interface constraint: Choose between the discrete safety interface X11 and the Ethernet safety interface X66 (PROFIsafe/CIP Safety), and they cannot be enabled simultaneously.

Cooling architecture: dual circuit heat dissipation; Heat exchanger cooling control electronic components; External fans directly dissipate heat to KPP/KSP and braking resistors; It is strictly prohibited to install filter cotton on the ventilation opening, as it may overheat and shorten the lifespan of the device.

Optional accessories: smartPAD installation bracket; Roller kit, limited to short distance movement inside the cabinet, prohibits vehicle dragging for long-distance transportation; Reserved TS35 DIN rail space in the cabinet for customers to install third-party components.

Technical Data

Mechanical parameters: overall dimensions of the machine (mm), ground mounting holes, technical cabinet, welding cabinet adapter opening drawings; Cabinet door opening angle: The maximum angle for a single cabinet is 180 °, and for parallel cabinets it is approximately 155 °; Minimum maintenance clearance for cabinets: ≥ 300   mm above, ≥ 50   mm on both sides, and ≥ 100   mm on the back; the overall weight and noise of the machine are approximately 65   dB (A).

Electrical parameters: Three phase 3 × 380/400V AC; Selection of fuses; External 24V PELV power supply specifications; The smartPAD cable can be extended in up to two sections, with a total length of ≤ 50 meters.

Environmental conditions: working+5~+45 ℃; Storage -25~+40 ℃ (with battery); When the altitude is greater than 1000 meters, the power will decrease by 5% for every 1000 meters increase; Vibration and impact indicators.

Electrical characteristics of SIB safety board: Input OFF interval -3-5   V; ON interval 11-30   V; 5-11   V undefined transition zone; Dual channel dynamic test output TA-A/TA-B; Pulse t1=625 μ s, period t2=106 μ s; maximum cable length of 50 μ m; relay design life of 20 years, with maximum switch frequency limit.

Warning label on nameplate: warning of residual high voltage in the intermediate circuit. The nameplate is strictly prohibited from being painted or removed.

REACH regulation SVHC high concern substance description; Safety performance EN ISO 13849-1 Cat.3/PL d, accompanied by PFH failure rate data.

Safety 

Legal and Liability: Robots are partially completed machinery; The system integrator shall undertake the risk assessment of the entire machine and issue an EC compliance statement; Modifying software and hardware without written permission from KUKA renders the warranty invalid.

Personnel grouping: System integrators, maintenance personnel, operators, all personnel must read the safety chapter.

Definition of danger zone: robot workspace+braking stop distance; Stop distance test conditions: With actual tool load, the equipment runs in a hot state for about 1 hour before testing, and the worst-case scenario result is taken.

Stop category

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

STOP1: Controller controlled deceleration shutdown, cutting off the drive after shutdown;

STOP1-DRS path directional braking shutdown;

STOP2: Keep the drive powered on and execute the static monitoring Safe Operational Stop after shutdown.

Four operating modes

Mode description

T1 manual deceleration mode, Cartesian maximum 250 mm/s, used for teaching programming

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

AUT control cabinet local automatic mode

AUT-EXT upper PLC external control automatic mode

Switching modes during program execution triggers STOP2.

Safety devices

Emergency stop – STOP; Three gear enable switch (middle position allows movement; fully press → STOP1; Release → STOP2); Enable the switch to undergo a complete functional test at least once a year.

External emergency stop must be configured, and the local emergency stop will fail after unplugging the teaching pendant.

External safety door, external enable, external safety stop input.

T1 mode speed monitoring: axis speed+Cartesian flange speed monitoring.

Multiple protection measures: jog Jog mode, software limit switch, mechanical hard limit, optional mechanical shaft limit; Manual movement of the robotic arm without driving energy is only for emergency personnel rescue and may damage the motor brake. Brake function testing must be conducted afterwards.

Start up mode: T1 jog when external security protection is not ready; Shielding external security protection, only for debugging and troubleshooting, personnel are strictly prohibited in hazardous areas; There are differences in the behavioral logic of KSS software versions; The Ethernet secure interface will limit the startup mode when connected online.

SPOC single point control principle: Submit interpreter, PLC, OPC, WorkVisual online configuration, test mode prohibits rewriting motion related variables to prevent unexpected actions.

Safety points for each working condition

IT Security: It is recommended to deploy information security management;

Debugging: Change default password; After the machine data is changed, it must be verified through practical operation; Special mechanisms such as coupling shafts and servo guns require specialized testing;

Manual mode: New/modified programs prioritize T1 low-speed testing; Multiple people entering the protected area, each equipped with an independent external enabling device;

Maintenance: Power off and lock the entire machine; High voltage in the intermediate circuit, power off and wait for at least 5 minutes for discharge; Strict ESD anti-static measures;

Reference the complete set of EU international standard lists (Machinery Directive 2006/42/EC, EMC, EN ISO13849-1, EN60204-1, etc.).

Planning and Design 

EMC electromagnetic compatibility: All external cables use shielded cables, and the shielding layer is extensively crimped with PE bars; The control cabinet belongs to Class A industrial equipment.

Installation conditions: independent floor standing, cabinet group arranged side by side; Adhere to the minimum maintenance gap; Only power grids with grounded neutral can be used, and non grounded neutral systems are prohibited.

Power parameters: specifications of the main power supply, selection of fuses, and recommended selection of residual current protection devices (universal selective type B).

PE equipotential mandatory requirement: robotic arm ↔ 16mm ² cable between control cabinets; The control cabinet body to the PE row of the distribution cabinet is also 16   mm ²; After installation, a fault circuit impedance test needs to be conducted in accordance with EN60204-1.

Motor connector (with the largest proportion in this chapter, compatible with up to 16 axes)

The document provides a massive number of connector pin assignments and servo module mapping combinations, covering standard 6-axis, heavy-duty Titan, palletizing robots, and external axes; Supports X20 body connector, X7 single external axis, X81/X82/X83/X84 multi axis combination connector, and supports all configuration schemes from 3-axis to 16 axis; RDC box supports cascading.

X20 series: main mechanical arm motor;

X7 series: single external axis;

X81-X84 multi axis connector, realizing multi external axis expansion, up to 16 axes;

Titan heavy-duty robot specific X20.1/X20.2/X20.3 connector;

RDC box cascade wiring example diagram.

X11 Discrete Security Interface (50 core D-Sub Han connector)

Dual channel dynamic pulse test TA-A/TA-B;

External emergency stop, safety door, external enable switch; Complete wiring schematic and dynamic pulse timing diagram;

The safety gate must be equipped with a confirmation button outside the fence, and automatic reset and operation are prohibited when the door is closed;

The test output TA-A/TA-B is only used to supply power to the safety input of this board, and external loads are prohibited.

X66 Ethernet safety interface (PROFIsafe/CIP Safety, SafeOperation option): complete input/output byte bit definition; Unused reserved bits are recommended to be forced to write 1 to avoid unexpected downtime; Schematic diagram of enabling switch wiring.

CIB board EtherCAT interface X44/X65.

System hardware change rules: When replacing hard drives, boards, adding or deleting axes/peripherals, the system must be reconfigured using WorkVisual software.

Transportation

Four transportation methods: lifting with lifting rings, forklift, pallet handling, and optional rollers;

Transportation prerequisites: power outage, removal of all cables, closure of cabinet doors, upright placement, installation of anti tipping brackets.

Lifting rings: 4 M10 lifting lugs; The requirement for the angle of the lifting equipment is that it is prohibited to hang diagonally.

Forklift: Use the bottom fork slot of the cabinet; The version with transformer only allows pallet lifting and prohibits long-distance forklift transportation.

Roller kit: Only for short distance movement inside the cabinet, vehicle dragging and transportation are strictly prohibited as there is a risk of tipping over.

Power on and Debugging (Complete Power on Process)

Visually inspect the entire machine, confirm that there is no damage during transportation, there is no condensation inside the cabinet, and the temperature is suitable for the ambient temperature.

Install the control cabinet in place to ensure maintenance of ventilation gaps.

Wiring and laying:

Motor cable, X21/X21.1 RDC data cable; Separate the wiring of motor cables and data cables; Comply with cable bending radius: fixed laying 3-5 x wire diameter; Drag chain 7-10 x wire diameter.

The length difference of cables in each channel of RDC is ≤ 10 meters.

Install the smartPAD bracket and plug in the teaching pendant X19.

Connect the PE equipotential to complete the grounding continuity test.

Restore battery discharge protection plug X305.

Harting X1 is connected to the three-phase main power supply.

Plug in the safety interface X11 in power-off state (hot plugging is prohibited).

After hardware modifications, WorkVisual downloads the project configuration; Enable Start up startup mode as needed.

Clear the dangerous area of personnel and objects, release the emergency stop, and turn on the power.

Power on forced function verification: complete safety function testing including emergency stop, all enable switches, mode switches, safety outputs, etc.

Unplug the teaching pendant and the emergency stop of the machine will fail; Reconnect and wait for about 30 seconds. The emergency stop and third gear enable switches must be retested.