Kuka KR C1 Manual
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Kuka KR C1 Manual

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SOFTWARE
KR C1
Hardware
Release 2.2
Hardware R2.2.8 11.98.02 en
1 of 70

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  • Page 1 SOFTWARE KR C1 Hardware Release 2.2 Hardware R2.2.8 11.98.02 en 1 of 70...
  • Page 2 KUKA Roboter GmbH e Copyright This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in the case of a replacement or service work.

  • Page 3: Table Of Contents

    Contents Control cabinet ..........General maintenance .
  • Page 4 Hardware Supply connection X1, service socket X01 ......... Motor connector X20, axes 1 to 6 .

  • Page 5: Control Cabinet

    Control cabinet Control cabinet General maintenance With the exception of battery replacement, the controller (processor unit) is maintenance-- free. Preventive maintenance is recommended wherever dirt, corrosion and wear occur. Before maintenance or repair work is started, it must be ensured that the incoming power cable is deenergized and that measures have been taken to prevent it from being inadvertently energized again.

  • Page 6: Structure

    Hardware Structure The controller contains all the components and functions which are required to operate the robot. It comprises the processor and power units, which are both installed in a common con- trol cabinet. 1.2.1 Processor unit The processor unit includes the modules highlighted in Fig. 1. CD and floppy drives Swing frame Interfaces...

  • Page 7: Power Unit

    Control cabinet (continued) G Standard PC Hardware With its powerful Pentium processor and main memory, the standard PC hardware forms the basis of the processor unit. The standard PC also includes a hard disk for storing the entire control software, including online help and online documentation, a floppy disk drive for archiving purposes and a CD--ROM drive for reading the CD--ROM supplied in the cabinet.
  • Page 8 Hardware Cabinet viewed from front Cabinet viewed from rear Ballast resistors with Doors closed ventilation Rear panels removed Covering removed Ballast resistor Temperature sensor External fan Transformer Transformer (optional) Fig. 2 Control cabinet Hardware R2.2.8 11.98.02 en 8 of 70...
  • Page 9 Control cabinet (continued) Cabinet viewed from front Internal fan with swing frame without swing frame Top--mounted cabinet PM0- -600 Basic module PM1- -600/25 (PM1- -600/25/16) Servo power module PM1- -600/25/16 Main switch Internal fan Basic cabinet PM6- -600 Servo power module Power infeed with FE201 mains filter...
  • Page 10 Hardware The control cabinet is divided into two independent cooling zones. The inner zone, containing the entire control electronics, is cooled by a heat exchanger or an air conditioner (optional). In the outer zone, the transformer (optional) and the heat sinks of the power module and the power supply modules are cooled directly by ambient air.

  • Page 11: Cooling By Heat Exchanger

    Control cabinet (continued) 1.2.3 Cooling by heat exchanger Rear view Front view Heat flow Heat flow Outer circuit Inner circuit 1 = Heat exchanger 2 = Fan, inner circuit 3 = Fan, outer circuit Fig. 4 Cooling by heat exchanger Hardware R2.2.8 11.98.02 en 11 of 70...

  • Page 12: Cooling By Air Conditioner

    Hardware 1.2.4 Cooling by air conditioner See air conditioner (optional) 69--000--456 Peripheral interfaces, general See peripheral interfaces (optional) Power unit interfaces The connector panel in the control cabinet is available in a variety of configurations depend- ing on the version concerned. Power unit equipment When replacing the power modules it must be ensured that the motor connectors are re--inserted in the correct positions (see LEERER MERKER,...

  • Page 13: Basic Modules And Servo Power Modules

    Basic modules and servo power modules Basic modules and servo power modules The basic and servo modules are designed for use as external axes or for special applica- tions. The structure and internal parts are comparable with those of the six--axis power mo- dule PM6--600.

  • Page 14: Basic Module Pm0--600

    Hardware Basic module PM0--600 The PM0--600 incorporates: G Clocked, controlled low voltage supply for the following modules -- Periphery (27 V DC / 6 A + 4 A, individually fused) -- PC (27 V DC / 6 A, backed up by external batteries) -- Equipment within the cabinet (27 V DC / 4 A) -- Holding brake for motors (26.5 V DC / 7.5 A) -- Lead battery for backing up the PC (26.8 V DC) incl.

  • Page 15: Power Supply Module Pm0--600

    Basic modules and servo power modules (continued) Power supply module PM0--600 Individual axis switch--off Mains connection 3x400V AC Control voltage 27,1V 10AT Ballast resistor 26,5V PM0--600 10AT 26,5V 6A Control voltage 26,5V ENABLE 26,5V 4A 6,3AT = Fuse 24V 6A X101 26,5V 4 1 2 3...

  • Page 16: Individual Axis Power Module Pm1--600/25

    Hardware Individual axis power module PM1--600/25 Control voltage and driver supply Control signals Int. circuit voltage X301H1 X507 X315 Motor 1 size A0 and A X301H2 PM1--600/25 X508 = LED SWITCH 1 Motor 1 = Monitor size B and C X301M SWITCH 2 X505...

  • Page 17: Connection Diagram For Pm 0 + Pm2 (Without Pm6--600)

    Basic modules and servo power modules (continued) Connection diagram for PM 0 + PM2 (without PM6--600) Individual axis switch--off to plug X12 X203 Voltage to open brakes 27,1V 10AT X101 Mains con- 26,5V PM0--600 10AT nection 3x400V AC 26,5V 6A 26,5V DSEAT ENABLE...

  • Page 18: Jumpering Of The Motor Connectors

    Hardware 2.7.1 Jumpering of the motor connectors The motor connectors are inserted in accordance with the robot type connected. Plug position (H1 / H2) : (RMS) = 64 A Plug position (M) : (RMS) = 32 A Plug position (L) : (RMS) = 16 A The controller detects the connector position and signals an incorrectly connected motor cable.

  • Page 19: Current Regulator Programming ($G_Coe_Cur) Of The Powermodule

    Basic modules and servo power modules (continued) Current regulator programming ($G_COE_CUR) of the Powermodule The powermodules PM0 and PM6 contain a programmable potentiometer (EEPot), with which the current regulator can be optimized for the appropriate robot type. The optimum value for this setting is entered in the machine data ($G_COE_CUR). When exchanging a PM0--600 , PM6--600 or a KRC1--control cabinet with powermodule, the correct current settings should be taken over and saved on the new powermodule.
  • Page 20 Hardware Overcurrent Overvoltage Heat sink temp. Ballast fault Internal temp. Connector position Brake fault Rapid gauging Battery ID- -Code Watchdog Ballast ON Undervoltage Data + addresses PC connection Current Register controller Reset Reset logic & Oscillator Internal temp. Control board Overcurrent Switched--mode power supply actual...

  • Page 21: Safety Logic Module Fe201

    Safety logic module FE201 Safety logic module FE201 Incorrect settings of the DIP--FIX switches X1 --X10 can lead to dangerous malfunctions of the robot in certain circumstances ! Before switching the controller on, it is therefore imperative to check the settings of the DIP--FIX switches X1 -- X10 again according to the adjustment instructions in this section! If these instructions are not observed there is a risk of extensive damage to the...

  • Page 22: View Fe201 Version A

    Hardware View FE201 version A ”Drives ON” relay with LED Connector interface Voltage supply connector “Drives ON” relays of MFC with LED ”27 V voltage monitoring” relays with LED FK connector PM... for external axes (optional) ”Test” relays with LED DIP--FIX switches X7--X9 FK connector PM...

  • Page 23: View Fe201 Version B

    Safety logic module FE201 (continued) View FE201 version B ”Drives ON” relay with LED “Drives ON” relays of MFC with LED ”Test” relays with LED Connector Voltage supply connector interface ”27 V voltage monitoring” relay with LED DIP--FIX switch X10 FK connector PM...

  • Page 24: Emergency Stop And Safety Circuit

    X921 external FE201 X921 X921 X923 X923 X923 X807 X807 X807 X806 X806 X806 X19M1 X19M1 X19M1 Emergency Stop Enabling X806 X806 X806 X806 X806 X806 X806 X806 X807 X807 X807 X807 X923 X923 X923 X923 X921 X921 X921 X921 X921 X921 external...

  • Page 25: Drives On/Off Circuit

    Safety logic module FE201 (continued) Drives ON/OFF circuit Hardware R2.2.8 11.98.02 en 25 of 70...

  • Page 26: Operating Mode Switchover

    Hardware Operating mode switchover Hardware R2.2.8 11.98.02 en 26 of 70...

  • Page 27: Individual Axis Switch--Off For External Axes

    Individual axis switch--off for external axes Individual axis switch--off for external axes This unit allows the external axis to be switched off independently of the robot axes by means of hardware. For this purpose, the driver voltage for the converter output stage and the supply voltage to the brake are disconnected.

  • Page 28: Fault With Power Unit Pm0--600 Series "1" And "2

    Hardware Fault with power unit PM0--600 series “1” and “2” If, while an external axis is running, a second or third external axis is switched off and on again (with the aid of the individual axis switch--off function), an error message “Overcurrent axis X”...
  • Page 29 Individual axis switch--off for external axes (continued) Fig. 12 Wiring diagram -- switch--off for external axes Hardware R2.2.8 11.98.02 en 29 of 70...
  • Page 30 Hardware Fig. 13 Circuit diagram X931 -- X604 Hardware R2.2.8 11.98.02 en 30 of 70...
  • Page 31 Individual axis switch--off for external axes (continued) Fig. 14 Outputs Hardware R2.2.8 11.98.02 en 31 of 70...
  • Page 32 Hardware Fig. 15 Inputs Hardware R2.2.8 11.98.02 en 32 of 70...
  • Page 33 Individual axis switch--off for external axes (continued) Fig. 16 Cross connections Hardware R2.2.8 11.98.02 en 33 of 70...
  • Page 34 Hardware Hardware R2.2.8 11.98.02 en 34 of 70...
  • Page 35 Hardware R2.2.8 11.98.02 en 35 of 70...

  • Page 36: Connector Panel / Peripheral Interfaces

    Hardware Connector panel / Peripheral interfaces For the purpose of operating the robot in a stand--alone mode or with an external controller, or of controlling peripheral equipment through the robot system, the connectors X1, X20, X11, X21 and X19 are provided. These connectors have the following functions: Supply connection Han6 HsB X01: Service socket (optional) X20: Motor connector, axes 1 to 6...

  • Page 37: Explanation Of Symbols

    Connector panel / Peripheral interfaces (continued) Explanation of symbols electronic output electronic input, logic ”1” 15V - - 30V DC 15 V - - 30 V (approx. 6.5 mA at 24 V) load current for 2 A output min.: 0.02 A max.: 2 A relay coil 18 V - - 30 V relay contact max.
  • Page 38 Hardware Safety circuit channels 11 / 12 Floating contacts of the safety cir- Is closed if the safeguard input is 1 and 2 29 / 30 cuit closed during automatic operation or if the safety switch is pressed in the Test mode. Test and Automatic 48 / 46 Floating contacts of the operating...

  • Page 39: Emergency Stop Circuit

    Connector panel / Peripheral interfaces (continued) Emergency Stop circuit The following examples show how the robot Emergency Stop circuit can be linked to other robots or with the periphery. 0V internal 24V internal Em. Stop channel 1 I Em. Stop channel 1 O Em.
  • Page 40 Hardware 0V internal 24V internal Em. Stop button periphery Em. Stop channel 1 I Em. Stop-- Em. Stop channel 1 O switching device Em. Stop channel 2 I Em. Stop channel 2 O Em. Stop relay channel 1 Em. Stop relay channel 2 Em.

  • Page 41: Supply Connection X1, Service Socket X01

    Connector panel / Peripheral interfaces (continued) Supply connection X1, service socket X01 Incoming supply 3x400V 50/60Hz 25A 3x415V 50/60Hz 25A only with transformer: 3x440V 50/60Hz 25A 3x480V 50/60Hz 25A 3x500V 50/60Hz 25A 3x550V 50/60Hz 25A * N--conductor is only required for optional service socket on 400V mains Fig.

  • Page 42: Motor Connector X20, Axes 1 To

    Hardware Motor connector X20, axes 1 to 6 Motor A1 U Motor A1 V Motor A1 W Brake A1 26V Brake A1 0V Motor A2 U Motor A2 V Motor A2 W Brake A1--6 26V Brake A1--6 0V Motor A3 U Motor A3 V Motor A3 W Brake A1--6 26V...

  • Page 43: Motor Connectors X7.1, X7.2, X7.3 (Optional)

    Connector panel / Peripheral interfaces (continued) Motor connectors X7.1, X7.2, X7.3 (optional) X7.1 Motor A7 U Motor A7 V Motor A7 W Brake A7 26V Brake A7 0V Housing Fig. 21 Motor connector X7.1 X7.2 Motor A8 U Motor A8 V Motor A8 W Brake A8 26V Brake A8 0V...

  • Page 44: Peripheral Connector X11

    Hardware Peripheral connector X11 0V internal +24V internal 0V internal 600 mA +24V internal EM. STOP +24V internal 600 mA EM. STOP channel 1 I EM. STOP channel 1 O 600 mA EM. STOP channel 2 I EM. STOP channel 2 O EM.
  • Page 45 Connector panel / Peripheral interfaces (continued) 0V internal +24V internal Rapid gauging channel 1 Rapid gauging channel 2 Rapid gauging channel 3 Rapid gauging channel 4 Rapid gauging 0V Cross connection 1 Cross connection 2 Cross connection 3 Cross connection 4 Cross connection 5 Cross connection 6 Cross connection 7...
  • Page 46 Hardware 0V internal +24V internal Output 1 (100mA) Output 2 (100mA) Output 3 (100mA) Output 4 (100mA) Output 5 (100mA) Output 6 (100mA) Output 7 (100mA) Output 8 (100mA) 0V output 1--8 +24V output 1--8 Output 9 (100mA) Output 10 (100mA) Output 11 (100mA) Output 12 (100mA) Output 13 (100mA)
  • Page 47 Connector panel / Peripheral interfaces (continued) 0V internal +24V internal Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 0V input 1--8 Input 9 Input 10 Input 11 Input 12 Input 13 Input 14 Input 15 Input 16 0V input 9--16...

  • Page 48: Peripheral Connector X12 (Optional)

    Hardware Peripheral connector X12 (optional) 0V internal +24V internal Cross connection 1 Cross connection 2 Cross connection 3 Cross connection 4 Cross connection 5 Cross connection 6 Cross connection 7 Cross connection 8 Cross connection 9 Cross connection 10 Cross connection 11 Output 1 (100mA) Output 2 (100mA) Output 3 (100mA)
  • Page 49 Connector panel / Peripheral interfaces (continued) 0V internal +24V internal Output 17 (2A) Output 18 (2A) Output 19 (2A) Output 20 (2A) 0V output 17--20 +24V output 17--20 Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 0V input 1--8...

  • Page 50: Can Bus Sub--D Connector X801

    Hardware CAN bus Sub--D connector X801 X801 not assigned CAN low signal of first controller CAN bus GND of first controller not assigned not assigned not assigned CAN high signal of first controller not assigned not assigned Fig. 30 CAN bus Sub--D connector X801 5.10 Ethernet Sub--D connector X802 X802...

  • Page 51: Data Cable Connector X21, Axes 1 To 8

    Connector panel / Peripheral interfaces (continued) 5.11 Data cable connector X21, axes 1 to 8 n. c. +24V /CLKo CLKo /FSi /FSo /CLKi CLKi n. c. n. c. Housing Fig. 32 Data cable connector X21 Hardware R2.2.8 11.98.02 en 51 of 70...

  • Page 52: Data Cable Connector X8, Axes 7 To 12 (Optional)

    Hardware 5.12 Data cable connector X8, axes 7 to 12 (optional) n. c. +24V /CLKo CLKo /FSi /FSo /CLKi CLKi n. c. n. c. Housing Fig. 33 Data cable connector X8 Hardware R2.2.8 11.98.02 en 52 of 70...

  • Page 53: Kcp Connector X19

    Connector panel / Peripheral interfaces (continued) 5.13 KCP connector X19 Display screen KCP + Display screen KCP -- CAN bus + CAN bus -- TxD + TxD -- RxD + RxD -- EM. STOP 2 OUT EM. STOP 2 IN EM.

  • Page 54: Jumpers For Stand--Alone Operation X11

    Hardware 5.14 Jumpers for stand--alone operation X11 0V internal +24V internal EM. STOP Fig. 35 Jumpers for stand--alone operation X11 Hardware R2.2.8 11.98.02 en 54 of 70...
  • Page 55 Hardware R2.2.8 11.98.02 en 55 of 70...

  • Page 56: Digital Servo Electronics (Dseat)

    Digital Servo Electronics (DSEAT) Description of the DSEAT In the KR C1 the main processor is responsible for all controller tasks except the drive control functions, which require very short cycle times that would overload the main processor. The- refore the drive control functions (position controller, speed controller, etc.) are implemented on a separate slot--in card (or possibly two separate cards).

  • Page 57: Block Diagram Of The Dseat

    Digital Servo Electronics (DSEAT) (continued) Block diagram of the DSEAT The DSEAT consists of a DSP (Digital Signal Processor), RAM, EEPROM and interfaces to the RDC and to the PM6--600. Interface connector to MFC EEPROM Dual port RAM 8Kx8 2Kx16 Processor TMS320C32 Address...

  • Page 58: Dseat Functions

    Hardware DSEAT functions Actual position sensing: Resolvers are used as the encoders for position sensing. The encoder signals are conditio- ned on the RDC module. The DSEAT then receives the actual position values via a serial interface in the form of digital signals transmitted at the rate of the position controller clock (2 ms), i.e.

  • Page 59: Configuration Of The Dseat

    Digital Servo Electronics (DSEAT) (continued) Configuration of the DSEAT Boot from dual port RAM Watchdog LEDs (at rear) Fig. 38 (Rough) View of the DSEAT card Connectors X810 Connection for MFC 50--pin X811 Connection for PM6--600 40--pin X812 Connection for RDC 15--pin JP2: Connection for test adaptor (only for developers)

  • Page 60: Function Test Of The Dseat Card

    6.7.2 Function test of the DSEAT with the ”DSERDW” diagnostic tool Quit the KR C1 user interface by clicking the mouse on the status bar. Confirm the dialog window with the ”ICON” entry by clicking ”OK”. Minimize any other running applications.

  • Page 61: Resolver--To--Digital Converter (Rdc)

    Resolver--to--Digital Converter (RDC) Resolver--to--Digital Converter (RDC) Description of the RDC The RDC card with built--in DSP (Digital Signal Processor) is located in a housing at the base of the robot and performs the following functions: Generation of all necessary operating voltages from the 27V supply; Resolver power supply for 8 axes;...

  • Page 62: Block Diagram Of The Rdc

    Hardware Block diagram of the RDC Resolver interface Motor temperature A6 E1 E2 sin cos 12 V Multiplexer 16:1 Multiplexer 16:1 Sine--wave sin sampling cos sampling generator EEPROM 8 kHz 8Kx8 EE--pot. amplitude adjustment Driver Logic, DSP Amplifier Multiplexer Processor TMS320C32 A/D converter 60 MHz DC DC...

  • Page 63: Operating Principle Of The Rdc

    Resolver--to--Digital Converter (RDC) (continued) Operating principle of the RDC Power supply unit: The 27V supply voltage generated in the PM is fed via the encoder cable to the power supply unit, which adapts it to provide all the voltages required by the RDC: +5 V Processor, logic components, temperature sensors +12 V...
  • Page 64 Hardware EMT interface: The two channels of the EMT are read as binary inputs and transmitted in serial mode to the DSEAT together with the actual values and motor temperatures. A Lemosa (5--pin) connector is used for the EMT interface. Serial connection from DSE X812 to RDC X31 Data communication with the DSEAT is implemented by a synchronous serial interface (SSI interface with RS422/485 drivers).

  • Page 65: Configuration Of The Rdc

    Resolver--to--Digital Converter (RDC) (continued) Configuration of the RDC Metal screw JP1: write protection of EEPROM boot area protected (default) writeable Plastic screw Watchdog LED JP2: interrupt jumpering 1--2 INT3 2--3 INT0 (default) Metal screw Fig. 40 Configuration of the RDC card RDC interfaces Connector: Lumberg Resolver, axis 1...

  • Page 66: Lumberg Connectors On Rdc Per Axis For Resolver Cables X1 To X8

    Hardware 7.5.1 Lumberg connectors on RDC per axis for resolver cables X1 to X8 Assign- Pin--Pin R [Ohm] ment 1 -- 2 588 (at 25_C) 1000 (at 100_C) 4 -- 5 36 (Type B) otherwise 53 6 -- 7 48 (Type B) otherwise 147 8 -- 9 48 (Type B) otherwise 147 Removing/Installing the RDC...

  • Page 67: Function Test Of The Rdc

    7.7.2 Function test of the RDC with the ”DSERDW” tool Quit the KR C1 user interface by clicking the mouse on the status bar. Confirm the dialog window with the ”ICON” entry by clicking ”OK”. Minimize any other running applications.

  • Page 68: Simulating Emt Mastering

    Hardware The 10th word (value) is the motor temperature of axes 1--8, requested by the DSE in the command. Normally, this value should vary. The 11th word (error) shows the error bits and EMT signals. Bits 0 to 7 are the error bits of axes 1 to 8.

  • Page 69: Rdc Calibration

    ”20000” (default setting). Quit ”dserdw.exe” by pressing ”Esc” and open KR C1 (ICON). When the KR C1 controller is running, all axes must travel through at least one motor revolution. Exit the KR C1 user interface again, as described above.

  • Page 70: Memory Test

    Hardware 7.7.2.5 Memory test Return to the main menu by pressing ”Esc”. Select menu option [1] and note down on paper a few values from items 104 to 135 of the table. Make sure that the back--up battery is connected. Exit ”dserdw.exe”...
  • Page 71 Index CAN bus Sub--D connector X801, 50 Connector panel, 36 Data cable connector, 51 Emergency Stop circuit, 39 Ethernet Sub--D connector X802, 50 Interface signals, 37 Jumpers for stand--alone operation, 54 KCP connector X19, 53 Peripheral connector, 48 Peripheral interfaces, 36 Service socket X01, 41 Supply connection X1, 41 Index -- i...

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