2.9 KUKA KR C4/C5 Controller Configuration

Supported Controller Model(s)

Controllers

KUKA KR C4

KUKA KR C4 is the current prevalent series that runs system software KSS8.6

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KR C4 controller series

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KUKA KR C5

KUKA KR C5 are newer controller series with system software KSS8.7

Supported robots:

• KR CYBERTECH nano/ nano ARC/ ARC

• KR IONTEC

• KR QUANTEC

• KR FORTEC

• KR 1000 titan

• Palletizing robots

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Network Setup

KUKA requires two interfaces to communicate:

• KLI Interface

  • Communicates with PLC

  • Required for exchange of safety signals via Profisafe

  • Required for exchange of standard inputs-outputs via Profinet for starting the robot programs from PLC in EXT Mode

  • Interface to program the robot with Workvisual. (Programming software from KUKA)

• RSI Interface

  • Communicates with the RTR controller

  • All the commands from the RTR controller are received by the robot via this interface

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RSI 3.2
Updated: Aug 29, 2024

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KRC Files for RSI 4.1 and above
Updated: Aug 29, 2024

Setting up the RSI Network Interface

• Make sure that the controller is in T1 mode. To access the menu, rotate the key at the top of the Teach Pendant (TP) clockwise. Rotate the key back to the top position when done.

• Elevated user permissions are required to modify the network settings. Click the User icon (the mouse is hovering over it) to access the list of users. The default password for the Administrator user is Kuka.

• Open the settings menu by clicking the bottom-right most physical button on the TP

  1. Go to Start-up

  2. Under the Start-up menu select Network Configuration

  3. Click Advanced

• Click Add Interface on the bottom row

  • Set the Interface Designation to RSI or another desired name.

  • Select Mixed IP Address for the Address Type

  • Set the desired IP address and Subnet Mask.

  • Under Real-time Receiving Task, set the Reception Filter to UDP

  • Under Receiving Task, set the Reception Filter to the Target subnet

RSI Configuration Files

From the list of provided files (link on top of the page), RSI_EthernetConfig.xml and RSI_EthernetConfigMonitor.xml need to be configured before use. Open both files and change the IP_NUMBER to match the IP address of the RTR Controller. Modify the PORT number in both files if necessary.

Once all the files have been properly configured, They will need to be copied onto the KUKA controller. A flash drive is recommended to copy files onto the KUKA controller.

RTR Controller Configuration

• Set the Robot IP Address or Hostname to the address used in the KUKA Controller Network Configuration section

• Set the Realtime Controller IP Address or Hostname to the IP address of the RTR controller. This should match the address set in RSI_EthernetConfig.xml and RSI_EthernetConfigMonitor.xml

• Set the RSI Port to the port number configured in RSI_EthernetConfig.xml and RSI_EthernetConfigMonitor.xml

Usage Instructions

Ensure that the KUKA controller is in AUTO mode.

• Select the RSI_Ethernet.src program

• Load the project on the Control Panel. It is normal to not see any changes on the screen. The RTR Controller is waiting for the user to start the program.

• Press the Play button on the Teach Pendant three times to run the program. If successful, the screen should change and the project will successfully load.

Task-manager setup (eg. PLC)

PLCs can act as task-manager to send move commands to robots via the RTR controller.

PLC HW Configuration (Siemens TIA Portal)

• Install the GSD files from above.

• Configure the IP address (KLI Interface) and connect the KUKA GSD to the network system.

Setting up communication: PLC ↔︎ KUKA

PLC Program to initiate Start-up Program on KUKA

Download the sample project attached below to copy PLC datatypes, DBs, and function blocks in your PLC program.

TCP Version (old)

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Profinet version

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Configuring Profinet communication with Workvisual

To start the KUKA robot programs from PLC, a profinet communication needs to be configured via Workvisual.

• Upload the existing program from the robot controller. File > Open Project > Browse > Controller Project.
  
  

   

• Add Profinet under the Bus Structure.
  
  

   

• Select the configuration, Profinet name, and the number of Profinet IOs, and select ProfiSafe/No ProfiSafe depending on the application.
  
  

   

• Import IO Configuration from pre-configured Profinet-KUKA IO connections.
  
  

   

• Pre-configured IOs with Profinet connections.
  
  

   

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Setting up Start-up Program on KUKA

The following changes need to be made on the KUKA side to enable the program to start from PLC.

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• Copy main_cell.src and standard.sub from sample KUKA Project

• Make the following changes at the end of the config.dat file. Do not copy the config.dat file from the sample project as it may overwrite some key parameters of the available robot.

Configuring the IOs for EXT Mode

Inputs and outputs for the robot to be controlled externally via PLC must be modified on the Robot pendant itself. They need to be mapped to the IO_configuration_template.xml we used.

• Turn the key on the robot pendant & switch the robot to T1 mode.

• Click on the robot icon on the left corner to open the menu. Navigate to Configuration > User group > Administrator to change user rights to admin. The default password is KUKA.
  
  

• Cancel the running program on the robot pendant, if any. Click on 'R' to reveal a drop-down menu that allows cancellation of the program.

• Navigate to Configuration > Inputs/Outputs > Automatic External to open the tab that shows the IO-mapped values.
  
  

   

• Shuffle the tabs to find all the inputs and outputs as shown below.

  The number in column ‘value’ needs to be edited to the ones shown below. Eg. Program start variable (system variable $EXT_START) needs to be changed from 1 to 91 in above example, based on the provided table below.
  
  

  KUKA is now ready to be controlled via PLC in EXT mode.