product data sheet/ installation instructions kuka

Product Data Sheet / Installation Instructions KUKA Connectivity Box

12.10.2018 KUKA Connectivity Box of 8

Product Data Sheet/ Installation Instructions

KUKA Connectivity Box

Table of Contents

1 Description of Product 2

2 Technical Data of the KUKA Connectivity Box 2

2.1 Product Data 2

2.2 Optional Accessories 2

2.3 Dimensions of the KUKA Connectivity Box 3

2.4 General Technical Data 3

2.4.1 Housing 3

2.4.2 Hardware Equipment 3

2.4.3 Electrical Data 4

2.4.4 Permissible Ambient Conditions 4

2.4.5 Standards, Specifications 4

3 Installation Instructions, Description of Hardware Interfaces 4

3.1 Overview and Arrangement of Interfaces 4

3.1.1 Description of Interfaces 5

3.1.2 Pin Assignment Voltage Supply XP1 5

3.1.3 Components on Front (under Front Panel) 6

3.1.3.1 Micro-USB Interface 6

3.1.3.2 Micro SD Memory Card Slot 6

4 Commissioning (Integration in Production Line and Machines) 7

4.1 Customer Requirements 7

4.1.1 Assembly of the KUKA Connectivity Box 7

4.1.2 Commissioning 7

4.2 Operation and Fault Diagnostics 7

4.2.1 Defined Blinking Frequency of the Status LEDs 8

4.2.2 Error Codes for Status LEDs 8

4.3 KUKA Contact, Support and Service 8



1 Description of Product

The KUKA Connectivity Box will be integrated into a robot, machine or production line, with the aim of obtaining remote access to devices in your production system with an IP address.

The KUKA Connectivity Box thus serves as the link and security component between the customer's system and KUKA’s service department in conjunction with the KUKA Cloud. KUKA is granted access to the data, programs and status of the machine via an enable switch (on the customer side).

Fig. 1: KUKA Connectivity Box

2 Technical Data of the KUKA Connectivity Box

2.1 Product Data

Product Data:

Short description of product: KUKA Connectivity Box Type HW V2.0

Description: VPN Router Hardware / without licence

KUKA Material Number: 1000731883

Customs Tariff No., Commodity Tariff No.: 84715000

Country of origin: EU

Weight: 130g (without packaging)

Internal Type Classification: C2-201

Other: with KUKA Serial Number

2.2 Optional Accessories

Power Supply Connector:

Type: 5-pole, 3.5mm grid dimension

Short description / description: PCB connector

KUKA Material Number: 1001410009

Customs Tariff No., Commodity Tariff No.: 85366990

Country of origin: Germany

Weight: 3.324g



2.3 Dimensions of the KUKA Connectivity Box

Dimensions: Relating to installation in control cabinet

Height: 99mm

Width: 24mm

Depth: 114.5mm

2.4 General Technical Data

2.4.1 Housing

Housing:

Design: Plastic housing, industrial standard

Type of fastening: 35mm DIN rail

Type of assembly: Intended for installation in control cabinet

Protection class: IP20

2.4.2 Hardware Equipment

Hardware Equipment:

CPU Board: Hardware Type C2 ARM Cortex A8, 32bit Hardware Phytec Board

Frequency: 1000MHz

RAM (memory): 512MB DDR3

Interfaces, Ethernet: 2 x 100MBit Ethernet Ports

Interfaces, USB port: 1x Micro-USB (OTG capable)

System flash card: Design Micro-SD, externally accessible



2.4.3 Electrical Data

Electrical Data:

Voltage supply: DC, external

Voltage range: 24V(nominal) (19.2V minimal – 28.8V maximal)

Power consumption: <10W, depends on operating status

Current consumption: max. 0.45A

max. fuse protection/pre-fuse protection: 2A

2.4.4 Permissible Ambient Conditions

Permissible Ambient Conditions:

Protection class: IP20

max. ambient temperature during operation:

0°C … +40°C

max. ambient temperature during transport and storage:

-40°C … +40°C

Permissible humidity: 10% … 95% (no condensation)

Permissible air pressure: 53 kPa ... 108 kPa (5000 m üNN)

Place of installation: Control cabinet, terminal box

Installation position : arbitrary

Required spacing: Stacks and rows possible, min. 20mm distance from e.g. cable duct

2.4.5 Standards, Specifications

Standards, specifications,:

Certification: CE mark

3 Installation Instructions, Description of Hardware Interfaces

3.1 Overview and Arrangement of Interfaces



3.1.1 Description of Interfaces

Description of Interfaces:

P1 XP1 Voltage supply

P2 XD11 (LAN) Connection to network (internal, to production line) (RJ45)

P3 XD2 (WAN) Connection to network (external, “Internet”) (RJ45)

P4 Not assigned, not used

3.1.2 Pin Assignment Voltage Supply XP1

P1 XP1, voltage supply

Pin 1 Vin, 24V DC +

Pin 2 GND (0V)

Pin 3 N.C.

Pin 4 N.C.

Pin 5 N.C.



3.1.3 Components on Front (under Front Panel)

Components on front (under front panel)

P5 Micro-USB interface For configuration, mobile Internet connection

P6 Micro SD memory card slot

P7 Reset button

Restarts the gateway. Note: A running, existing VPN connection will be interrupted by this action.

P8 2 Status LEDs For diagnostics and status

3.1.3.1 Micro-USB Interface

This has two functions:

Can be used optionally for a Surf-Stick solution with mobile Internet connection (GSM/LTE) (in agreement with KUKA).

For transferring configurations to the KUKA Connectivity Box and for reading log files.

3.1.3.2 Micro SD Memory Card Slot

The operating system of the KUKA Connectivity Box is stored on the memory card. Should there be a hardware malfunction, the memory card (with the complete configuration) can be transferred to another unit.

Caution: The Micro SD memory card can only be pulled out or inserted in a de-energized state (without 24V voltage supply). A memory card image can also be created, e.g. in order to archive a backup for the entire system.



4 Commissioning (Integration in Production Line and Machines)

4.1 Customer Requirements

The following preconditions are necessary for commissioning and operation:

Assembly and integration into the local network is carried out by the customer or as a part of a customer project.

Internet access will be provided by the customer. This can be done via Ethernet or mobile network.

4.1.1 Assembly of the KUKA Connectivity Box

Assembly of the KUKA Connectivity Box on a DIN rail in the control cabinet

Installation of 24V voltage supply

Establishment of the internal and external network connection

Commissioning of the software takes place in coordination and cooperation with KUKA’s Service Dept.

4.1.2 Commissioning

Commissioning of the software takes place in coordination and cooperation with KUKA’s Service Dept.

The appropriate technical agreements, e.g. IP addresses, are to be made in advance

Corresponding licences and software configurations will be provided by the Service Dept.

As an option, an external user access can be set up in consultation with KUKA’s Service Dept.

4.2 Operation and Fault Diagnostics

On the front panel the KUKA Connectivity Box has the following display and operating elements:

Status LED red (VPN) used for the (VPN) connection status

Status LED red (USB/Pwr) Power, boot status, USB and update status

Reset Button Restarts the gateway. Note: By doing this, a running, existing VPN connection will be interrupted.



4.2.1 Defined Blinking Frequency of the Status LEDs

Defined blinking frequency of the status LEDs

Blink 1 Heartbeat 100ms on; 100ms off





ON Steady light

OFF LED is off

4.2.2 Error Codes for Status LEDs

LED red (USB/Pwr) LED red (VPN) BIOS Code Error Messages

1 OFF OFF Reset Status / Loading the operating system

2 Blink 2 OFF Boot loader initialisation

3 Blink 2 ON General hardware fault

4 Blink 2 Blink 1 Micro SD memory card missing

LED red (USB/Pwr) LED red (VPN) Operating System Error Messages

5 Heartbeat OFF Recovery system is active

6 Heartbeat Blink 1 Error in recovery system

7 Heartbeat ON Initial check went well / Base system active

8 Blink 3 OFF Loading of operating system

9 Blink 3 Blink 1 Error during loading of operating system

10 ON OFF KUKA Connectivity Box in operation, no tunnel active

11 Blink 4 OFF A USB flash drive is inserted and can be used

12 Blink 5 OFF An update is in progress

13 Blink 1 OFF A error has occurred during the update

14 OFF ON VPN Tunnel CRSM Server (at KUKA) is established

15 OFF Blink 4 VPN Tunnel connection set up

16 OFF Blink 3 Internet connection set up

17 OFF Blink 1 VPN Tunnel is set up but problems with the network identified

4.3 KUKA Contact, Support and Service

Further information and support can be obtained from:

KUKA Deutschland GmbH Zugspitzstrasse 140

86165 Augsburg E-Mail: [email protected]

Telefon: +49 821 797 1926

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