Product Core Brief
- Model:
- Brand: KUKA Robotics (Germany)
- Series: Size 1 Servo Drive Family ⚠️ EOL, only original surplus/repair stock available
- Core Function: Execute high-dynamic closed-loop torque, speed and position control for medium-load robot joint servo motors; receive motion commands via Interbus from cabinet CCU, output three-phase variable frequency power to robot axesManualsLib
- Product Type: Cabinet-mounted single-axis servo amplifier (robot dedicated)
- Key Specs: 32 A continuous rated output current | 400 VAC three-phase mains input | Max 3.5 kW output power | Interbus master/slave bus interface | Compatible with KR C2 / KR C4 robot controllers | Part numbers: 00-105-351, 00-122-286 | Condition: New Original Surplus / Refurbished
Product Introduction
ThKA is a Size 1 single-axis servo drive designed exclusively for KUKA KR C2 and KR C4 robot control cabinets, used to drive medium-torque robot joints (arm, wrist axes) on 6-axis industrial manipulatorsManualsLib. It communicates with the central cabinet CCU via Interbus to receive real-time trajectory instructions, while reading motor encoder feedback to maintain precise closed-loop positioning.This unit sits between smaller -08/16 low-current drives and large -48/64 heavy-load models. It relies on natural convection cooling without auxiliary fans to reduce cabinet noise and maintenance points. OEM reliability testing records an MTBF of 98,000 operating hours under standard 40 °C cabinet ambient. It differs from third-party general servo drives by proprietary Interbus protocol and KUKA robot motion algorithm matching.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Rated Continuous Output Current | 32 A (model number suffix defines maximum axis current) |
| Mains Input | 3-phase 400 VAC ±10%, 50/60 Hz |
| Rated Output Power | 3.5 kW nominal, peak short-term overload capacity 200% |
| Control Modes | Torque loop, speed loop, position loop fully closed-loop cascade control |
| Communication Bus | Interbus (X13 IN / X14 OUT daisy-chain topology for multi-drive racks) |
| Motor Feedback Interface | Support KUKA proprietary resolver / incremental encoder |
| Cooling Method | Natural convection heat sink, no built-in cooling fan |
| Enclosure Protection Class | IP20 (cabinet internal mounting only; no outdoor installation) |
| Operating Ambient Temp | 0 °C to +55 °C; storage -25 °C to +70 °C |
| Safety Protection Circuits | Overcurrent, short-circuit, overvoltage, undervoltage, overheat, encoder loss, bus communication fault |
| Standard Part Codes | 00-105-351, 00-122-286 |
| Physical Form Factor | Size 1 compact vertical rack mount for KR C2/C4 cabinet slots |
| Main Connector Definition | X1: Mains DC bus; X2: Servo motor power; X8: Brake resistor; X13/X14: Interbus bus; X3: Motor temperature sensor + encoder feedback |
| Weight | Approx. 3.2 kg |
| Certifications | CE, UL, RoHS compliant, robot safety SIL2 qualified |
Quality Control Process (Engineer’s Perspective)
- Incoming Verification: Match serial numbers against KUKA original factory production records to filter counterfeit aftermarket copies. Visually inspect Interbus port connectors, motor power terminal screws, heat sink fins for deformation, and front panel status LED lenses for scratches.
- Live Functional Test: Install drive into a KR C4 test cabinet with matched KSP600 power supply and medium-load robot servo motor. Run a 24-hour soak cycle with cyclic robot trajectory programs; log bus communication stability, output current ripple and overheat protection trigger thresholds hourly.
- Electrical Parameter Test: Use a 500 V Megger to test insulation resistance between power terminals and chassis ground; pass threshold >10 MΩ. Verify short-circuit rapid latch protection and motor temperature sensor fault detection response.
- Firmware Verification: Read drive firmware version via KUKA WorkVisual software; record build number and match to robot controller software compatibility matrix. Photograph Interbus DIP switch termination settings for on-site commissioning reference.
- Final QC & Packaging: Place drive inside anti-static ESD foam packaging with original terminal dust covers. Affix dated QC Pass sticker listing insulation resistance test results and total soak runtime before warehouse storage.
Replacement Pitfall Guide
❗ Controller Compatibility Mismatch Risk:he only supports KR C2 and KR C4 cabinets. It cannot plug into newer KR C5 cabinets that use KSD2 series drives; mixing generations triggers permanent bus communication failure and robot E-stop.❗ Interbus Wiring Termination Misconfiguration Risk: The last drive in the Interbus daisy chain requires activated termination resistor via DIP switch. Unmatched termination creates signal reflection noise and random axis following error alarms during high-speed robot movement.❗ Mismatched Drive Current Rating Risk: Replacing -1th is mechanically possible, but robot motion software must re-calibrate axis current limits; unmodified parameters cause unnecessary overload fault trips.❗ Power Supply Headroom Miscalculation Risk: A fully ed draws peak 18 A from the cabinet DC bus. When multiple high-current axes run simultaneously, size the KSP power pack with 20% overhead; underrated power supplies trigger undervoltage safe stop.❗ ESD Damage Risk: Exposed X2 motor power and X13 Interbus connectors are ESD sensitive during cabinet disassembly. Use a grounded anti-static wrist mat during drive swapping in low-humidity workshop spaces; static discharge corrupts internal control PCB and generates intermittent encoder dropout faults.Keep these in mind and you’ll cut 90% of rework time.
Compatibility Matrix & Benchmarks
Compatibility Matrix
- KR C2 / KR C4 Robot Controller Cabi → : Direct Replacement — Native Interbus backplane topology, zero cabinet mechanical modification
- KUKA Medium-Torque Robot Servo Motors (3.0–3.5 kW a → : Native Matched — Proprietary encoder/resolver feedback pinout matching
- -16 (16A Small Servo Dr → : Needs Adaptation — Rack slot fits, robot axis current limit parameters must be re-tuned via WorkVisual
- KSD2 Series (KR C5 New Generation Dri → : Incompatible — Different bus protocol and cabinet backplane mechanical locking structure
Benchmarks
- Full-axis position loop response bandwidth: 1.2 kHz (nominal 400 VAC mains supply, medium inertial robot wrist load)
- Overcurrent short-circuit shutdown delay: <2 µs to protect motor windings and drive power IGBTs
- Continuous power consumption (standby): 28 W; full 32 A rated output steady-state draw: 3.4 kW
