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.
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.
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...
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.
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,...
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.
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.
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...
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.
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...
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...
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...
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...
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.
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...
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...
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...
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.
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...
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...
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...
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...
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...
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).
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...
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.
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)
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.
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;...
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...
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).
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.
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.
”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.
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...
Need help?
Do you have a question about the KR C1 and is the answer not in the manual?
Questions and answers