KUKA KR C5 Controller Assembly Instructions

Product Description

Complete set of robot: robotic arm body+KR C5 controller+smartPAD-2 teaching pendant+cables+software+options. The controller is divided into two physical units: Control Unit and Power Unit.

1) Control Unit

Includes mini CSP controller system panel (status LED: mode, run, fault, soft power button), SSD hard drive, microSD card, SYBperf system motherboard, optional three types of interface boards (IFBstd standard IO, IFBsafe safety IO, IFBsafext safety extension IO), internal cooling fan.

Attention: It is strictly prohibited to dismantle the power unit housing without authorization, as there may be fatal high voltage.

2) Power Unit

Includes external cooling fan, cooling fins, KSP-600 servo drive module (FCU-600 power unit+SCU-7-1L safety control unit); Responsible for generating intermediate DC bus voltage, motor and brake control, and monitoring of braking mode bus.

3) CK Customer Kinematics

The CK version controller can drive the KUKA motor, but it does not come with standard mechanical phone data and is used for customer customized mechanisms; If robot machine data is loaded, it is equivalent to a standard robot controller.

4) Interface Overview

Discrete security interfaces: XG58, XG11.1, XG11.3, XG13.1/XG13.2, XG42 reference switches;

Ethernet safety options: PROFIsafe/CIP Safety/FSoE;

Network interface group XF1-XF8: KSI, KLI-OT, KLI-IT, Daisy Chain cascading KEI EtherCAT、KONI；

Power supply category: XD1 main input power supply, XD2 UPS (24V uninterrupted, power-off controlled shutdown), XD3 braking resistor;

Motor/Brake: XD20 motor connector, XD10 brake connector;

XF21: RDC rotary to digital converter interface;

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

5) Cooling

Independent fan air cooling for control unit and power unit; The airflow should be divided into inlet and outlet, and the air duct should not be blocked.

6) Designated use and misuse

Purpose: To drive KUKA industrial robots and CK customer kinematic mechanisms.  

Misuse: Used as stepping on steps, operating beyond parameters, outdoors, explosion-proof, radioactive, underground mining environment. Misuse results in the loss of all warranty.

Security Chapter 

The controller belongs to partially completed machinery and cannot be put into production separately; The system integrator must complete a complete system risk assessment and issue an EC compliance statement. The safety function meets EN ISO13849-1 Cat.3/PL d; Prerequisite: Emergency stop, enabling device, and USS 2 contactor must undergo functional testing every 12 months; The design lifespan is 20 years.

1) Stop category (following EN60204-1)

STOP0: The safety controller directly cuts off the power supply to the drive and brake, and immediately stops the machine;

STOP1: Controlled braking stops, cuts off the drive/brake after stopping the machine;

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

2) Personnel Definition

Distinguish between system integrators, operators, debugging and maintenance personnel, and cleaning personnel; Only personnel who have received specialized training are allowed to install and debug hardware; Operators must read the safety documentation in its entirety.

3) Workplace, danger zone, safety zone

Dangerous zone=robot workspace+robot arm/external axis stopping distance; Physical protection isolation is necessary.

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

4) Operation mode

KUKA Standard Software KSS

Mode Usage Speed Limit

T1 manual deceleration teaching debugging TCP maximum 250 mm/s, overspeed triggers STOP0

T2 manual high-speed testing allows for speeds exceeding 250 mm/s, but teaching programming is prohibited

AUT machine automatic mode program setting speed

AUT-EXT upper PLC external automatic mode program setting speed

VSS Mass System Software

T1, T2, EXT (external automatic); Support E2/E22, E7 button bypass safety door, only for debugging use, with strict risk control.

5) Core security functions

Emergency stop

Local emergency stop: smartPAD-2 teaching pendant emergency stop;

Force additional configuration of external emergency stop: After unplugging the teaching pendant, the emergency stop on it becomes invalid; Press to execute STOP1.

Enabling device: smartPAD-2 has four three position enabling switches; Release the trigger STOP2; Press the panic button completely to trigger STOP1. Support external enabling XG58.

Operator safety (safety door monitoring): AUT/AUT-EXT effective; Opening the safety door triggers STOP1; Cannot close the door and reset automatically, external confirmation button is required.

T1 speed monitoring: axis speed monitoring (default rotation axis 30 °/s, straight line 250 mm/s); Cartesian TCP monitoring defaults to 250 mm/s; Speeding directly STOP0.

Additional protection: software limit, mechanical hard limit; Manually release the brake without driving energy (limited to rescue, damaged brake).

6) Safety points for various types of homework

IT Security: Controllers need to be included in enterprise information security management to prevent unauthorized access;

Startup mode: Allow bypass external security protection in T1 mode, used for debugging when the fence is not installed; Personnel must be restricted from entering the danger zone;

Manual mode T1/T2: New programs and modified programs must be prioritized for T1 verification; T2 mode personnel must all evacuate the danger zone;

To download the simulation program to a physical machine, T1 must be tested first;

Maintenance and repair: power off, lock and tag; The maximum voltage for the intermediate circuit is 800 VDC, and after power failure, it must wait for at least 5 minutes for discharge; Strict ESD anti-static measures;

SPOC single point control security: Submit interpreter PLC、OPC‑UA、 Remote tools; In T1/T2 mode, rewriting of motion and speed/magnification variables is prohibited in the background; Access control permissions for the $SPOC_MOTION-ENABLE signal must be enabled.

7) Reference standards

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

Technical Data

1) Basic parameters of the controller body

Protection level IP20 (controller module, not cabinet); Weight about 25 kg; noise<71 dB (A); The shell is RAL7011 iron gray.

Divided into AC AC version and DC DC version, with different connector code pins to prevent incorrect insertion;

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

Storage temperature -20~+60 ℃; No condensation during operation; Pollution level 2;

Vibration shock: Run 0.5g continuously and vibrate 10g (11ms half sine wave).

Different power loads of different models

Model: Maximum apparent power servo axis

S6/S7 5.0 kVA 7-axis

M6/M7 10.5 kVA 7-axis

L6/L7 14.0 kVA 7-axis

L3EA External Shaft Box 10.5 kVA 3-axis

AC power supply three-phase 380-480VAC, ± 10%, 50-60Hz; DC version 480-750 VDC (nominal 600V DC);

Leakage current ≤ 150   mA; fuse specifications vary with model.

2) Safety IO electrical parameters

Safe output: maximum 30   V; current 10-500   mA; cable maximum 50   m; 20-year design life of approximately 9.5 million switching cycles, module must be replaced upon reaching the end of life;

Safe input: 5-11V is an undefined transition interval; Disconnect from 3~5V; 11-30V conduction; Dual channel TA-A/TA-B dynamic pulse cycle detection.

3) Mechanical dimensions, nameplate labels

Controller module external dimensions; The nameplate, high voltage warning, and QR code KUKA Xpert link must not be torn off; REACH regulation SVHC substance information access KUKA Xpert.

Attention: The controller module itself has an IP20 rating and must be installed in the KR C5 series cabinet (compactcab/smallsizecab/dualcab/triplecab/quadcab) for use. The cabinet provides IP54 protection.

System Planning

1) EMC electromagnetic compatibility

Belongs to EN55011 Class A Group 1 industrial equipment; All external cables use shielded cables, and the shielding layer is extensively grounded.

2) Installation conditions

The controller is a drawer style pull-out module installed in the cabinet rack; It is necessary to ensure smooth ventilation at the inlet and outlet to prevent heat accumulation; There should be no conductive dust or condensation, and the cabinet should be used for protection in harsh environments.

3) Cable laying

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

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

After replacing the RDC robotic arm data cable, all axes must be recalibrated for mastering;

PE equipotential connection must be carried out in accordance with the cabinet manual.

4) Detailed explanation of all interfaces

XF1-XF8 Ethernet port group (SYBperf motherboard)

KSI (XF1): Service port, connected to WorkVisual, prohibited from accessing IT LAN; The longest cable is 100 meters;

KLI-OT: oriented towards PLC fieldbus (PROFINET/EtherNet IP);

KLI-IT: Used for backup, cloud monitoring OPC‑UA；

Daisy Chain: Multi robot RoboTeam connected in series;

KEI：EtherCAT， Connect to external slave stations and FSoE security;

KONI: Camera and option specific.

Security Interface

XG58: External enable switch+additional local emergency stop; Three position external enablement;

XG11.1: 2-channel safety input+1-channel safety output; External emergency stop and safety door;

XG11.3: Expand discrete secure IO, secure confirmation, secure stop 1/2, secure operation stop;

XG13.1/XG13.2: Used for SafeOperation/SafeRangeMonitoring security options; Alarm space, monitoring space input and output;

Important: If Ethernet security (PROFIsafe/CIP Safety/FSoe) is enabled, XG11. x and XG13. x discrete safety inputs will no longer be recognized and evaluated by the controller, and either option will be used.

XG11.2: US2 peripheral contactor control, three modes: PLC control/robot internal control/disable; Used to cut off the peripheral 24V load voltage.

XD2 UPS interface: 24V uninterruptible power supply, controlled shutdown achieved in case of power failure; Running without UPS can result in loss of configuration and location data.

XD3 brake resistor interface; XD1 main power input;

XF21: RDC interface, providing power to the RDC module of the robotic arm and EtherCAT communication;

XG33 rapid measurement input+”Drives ready” indicator light output;

XG12 non secure IO board: 16 inputs and 16 outputs; Support high/low side jumper switching; 24V PELV power supply.

5) Safety performance indicators

Safety function PFH<1 × 10 ⁻⁷, based on a 20-year lifespan; Prerequisite: Conduct all safety function tests annually.

Transportation

The weight of the controller module is about 25 kg; before transportation, unplug all cables, close the cover plate, and place it horizontally on a handcart for transportation; Ensure proper anti fall fixation to prevent impact and vibration. Prohibit savage falls.

Startup and restart 

Complete startup process

Check that the mechanical arm body and controller module are not damaged during transportation, and there is no condensation inside the cabinet;

Slide the controller module into the cabinet rack and lock it; The locking action automatically completes the docking of XD1, XD2, and XD3 backboards;

Complete PE equipotential grounding;

Install coding pins for motor cables to prevent incorrect insertion;

Connect the motor cable, RDC data cable, and safety interface XG11.1/XG58 (the safety interface must be powered off and plugged in);

Connect the smartPAD-2 teaching pendant;

Confirm that the UPS battery protection plug has been restored;

WorkVisual verifies project configuration; Hardware modifications (such as replacing boards or hard drives) must generate a new download project; Directly exchange boards of the same model;

Confirm that there are no people in the danger zone and all safety measures are in place; Close the main switch and power on;

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

Startup boot sequence: restore USB drive → external hard drive → internal SSD; Identifying an external hard drive will disable the built-in SSD.

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 operation: Disconnect and lock the main switch of the cabinet.

Maintenance 

maintenance cycle

Every 12 months

All emergency stop, enable switch, and USS contactor function tests;

IFBsafe/IFBsafext relay output test;

Test the function of the “Drives ready” indicator light;

Depending on the degree of dirt: clean the heat dissipation fins and fan;

10 years: Replace the button battery on the system motherboard.

Mandatory requirements for maintenance safety

Power outage, locking and tagging; Disconnect the incoming power supply; Wait for at least 5 minutes for the intermediate circuit to discharge (up to 800VDC); Implement the 5-step electrical safety method (power-off – anti closing – electrical inspection – grounding – isolating adjacent live parts);

ESD anti-static throughout the process;

Do not use compressed air or spray water to clean the controller; Only use solvent-free cleaning agents to wipe.

Repair 

Only the maintenance described in this manual is allowed to be carried out on site; Other repairs must be carried out by KUKA trained personnel; Only KUKA original spare parts can be used. On site replaceable projects, unified process: safe power-off operation → unlocking and extracting controller module → disassembling and replacing parts → restoring assembly → locking back module → power on test:

Cleaning of heat dissipation fins;

SSD solid state drive replacement;

System motherboard button battery replacement;

Replacement of interface board blade fuse;

IFBsafe safety interface board replacement;

IFBsafeext security extension interface board replacement;

IFBstd standard interface board replacement;

SYBperf system motherboard replacement;

Internal SSD storage replacement;

Power motherboard connection board replacement;

KSP-STA external axis interface card (L3EA driver box);

Replacement of control unit fan; Replacement of power unit fan module;

Replacement of nameplate panel.

Troubleshooting

KSP power unit alarm message; Mini CSP panel LED status and fault codes; System motherboard LED fault indicator light;

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

Discontinuation, storage, and disposal 

Retirement: Power off, disconnect all cables, and remove the controller module;

Storage: Indoor dry and dust-proof, remove batteries and store them separately, seal all interfaces;

Scrap: Electronic boards are treated as electronic hazardous waste, and batteries are recycled and disposed of in accordance with regulations. It is prohibited to dispose of household waste.