• Model: KPS‑600/20‑REL

• Order No.: 00‑110‑728

• Application: KRC2 cabinets for KR150 to KR300 robots

• Safety Type: Relay‑based (external safety relays)

2. Technical Specifications

Electrical

• Input: 3∼ AC 400 V / 480 V (±10 %), 50/60 Hz

  • Rated current: 25 A (rms)

  • Peak current: 95 A (rms, 0.5 s)

• DC Intermediate Circuit: 565–585 V DC

  • Rated: 20 A continuous

  • Peak: 64 A

• Control Output: 24 V DC / 27 V DC, 30 A max

• Power Rating: Approx. 12 kW

• Protection: Overvoltage, undervoltage, overcurrent, short circuit, overtemperature, ground fault

Mechanical & Environmental

• Dimensions (W × H × D): 200 × 120 × 100 mm

• Weight: 4.7 kg

• Protection Class: IP20 (cabinet installation)

• Operating Temperature: 0 °C to +55 °C

• Storage Temperature: −20 °C to +70 °C

• Cooling: Integrated forced‑air fan; ≥50 mm clearance required

Safety (REL)

• Safety Integrity: SIL1 / PLc (EN ISO 13849)

• STO Response Time: 20–50 ms (relay contact delay)

• Monitored Signals: E‑stop, safety doors (via external safety relays)

3. Connector Assignment (X1–X5)

X1 – Mains Input

• L1, L2, L3: Three‑phase AC

• N: Neutral

• PE: Protective earth

X2 – DC Intermediate Circuit

• DC+: 585 V DC positive

• DC−: 585 V DC negative

• Connects to X1 of all KSD1 servo drives

X3 – Control Voltage

• +24 V / 0 V: Control power for cabinet components

X4 – Battery & Brake

• BAT+, BAT−: Battery charging (2 × 12 V lead‑acid)

• BRK+, BRK−: External brake resistor

X5 – Servo Bus & Safety

• IBS IN / OUT: Interbus servo bus (to KSD1 drives)

• SAFE: Relay‑based safety I/O (E‑stop/safety door contacts)

4. LED Status Indicators (Front Panel)

LED1 (Red) – Fault

• Off: Normal operation

• On: Critical fault (overvoltage, overtemperature, internal failure)

• Flashing 3 Hz: Brake error

• Flashing 6 Hz: Safety trip (E‑stop/safety door open, relay contact open)

LED2 (Green) – Power OK

• Off: No power / processor inactive

• Flashing 1.5 Hz: DC bus <60 V

• On: DC bus >60 V (ready for operation)

5. Safety Instructions

• High Voltage Hazard: DC intermediate circuit up to 585 V.

  → Wait at least 5 minutes after switching off for capacitors to discharge before maintenance.

• Only qualified personnel may install or service this unit.

• REL Wiring: External safety relays must be wired dual‑channel for E‑stop/safety doors.

• Do not open, modify, or bypass internal components or safety relay circuits.

• Ensure reliable PE connection for cabinet, KPS, and all drives.

• Keep ventilation slots free; inadequate cooling causes overheating.

6. Installation & Wiring

1. Mount vertically in designated KRC2 cabinet slot.

2. Connect X1 to three‑phase mains (check phase sequence and PE).

3. Wire X2 (DC+/DC−) to DC bus distribution rail (KSD1 X1).

4. Connect X3 to 24 V DC control distribution.

5. Attach battery cables to X4 (BAT+/BAT−) and brake resistor to BRK+/BRK−.

6. Connect X5 IBS IN/OUT in daisy‑chain with KSD1 drives; wire safety relay contacts to SAFE (dual‑channel).

7. Tighten power terminals to 2.5 Nm.

7. Operation

• Power‑On: Mains ON → internal charging → DC bus energizes.

• Standby: Green LED2 ON (DC bus ready); red LED1 OFF (no faults).

• Drive Operation: Supplies stable 585 V DC to KSD1 drives during motion.

• Regenerative Energy: Dissipated via brake resistor (monitored by KPS).

• Safety Stop: On E‑stop/safety door open → external safety relays open → STO activates → DC bus cut (20–50 ms delay) → red LED1 flashes 6 Hz.

8. Maintenance

• Daily: Check LED status, fan operation, cable integrity.

• Weekly: Clean fan and vents; remove dust.

• Monthly: Retighten X1/X2/X4 power terminals (2.5 Nm).

• Quarterly: Verify battery charging voltage and brake resistor resistance.

• Annual: Inspect capacitors (bulging), fan wear, safety relay contact condition.

9. Common REL Faults & Troubleshooting

• LED1 Flashing 6 Hz: Safety trip → check E‑stop, safety door, or external safety relay wiring/contacts.

• LED2 Flashing 1.5 Hz: DC bus <60 V → check mains, cabinet fuses, or KPS internal fuse.

• LED1 On (Overvoltage): Mains too high, regenerative overload, or brake resistor missing/faulty.

• LED1 Flashing 3 Hz: Brake error → check BRK wiring or resistor.

• Overtemperature: Fan blocked, vents covered, or ambient >55 °C.