The KUKA PH1003-2840 is the Low-Voltage Power Supply Unit (PSU) for the KRC2 Edition 2005 (Ed05) controller.1

While the KPS 600 (which you may have seen in the cabinet) handles the high-voltage DC bus for the robot motors, the PH1003-2840 (manufactured by MGV) is responsible for the stable 27V DC supply that powers the controller’s logic boards, the PC, and the peripheral electronics.

Technical Specifications

This unit is a heavy-duty industrial switching power supply designed to handle the high-vibration environment of a robot cabinet.

Feature    Details

Manufacturer    MGV (Model: 15.8044.800)

KUKA Art.  No.    00-109-802 (also referenced as 00-109-032)

Input Voltage    3-phase AC (3 x 320V – 460V)

Output Voltage    27.3V DC (adjustable)

Output Current    40 Amps

Application    Logic power for KRC2 Ed05 / VKRC2 Ed05

PH1003-2840

Role in the Cabinet

The PH1003-2840 is essentially the “heartbeat” of the control system.  It powers:

PH1003-2840

The MFC/DSE cards (the “brains” you asked about earlier).

The KCP (Teach Pendant) display and controls.

The PC Chassis (Motherboard and Hard Drive).

The ESC (Electronic Safety Circuit) safety signals.

Common Troubleshooting

Because it provides the logic power, a failure here usually results in a “dead” controller or intermittent “reboot” loops.

No Display on KCP: If the KCP screen is black and there are no lights on the PC, check the input fuses for this power supply.

Overload (Red LED): If the output current exceeds 40A (due to a short circuit in the wiring or a bad gripper solenoid), the unit will shut down.

Voltage Drop: Over time, the capacitors can age.  If the output drops below ~24V, the PC might crash unexpectedly or the safety circuit (ESC) might trigger “Emergency Stop” errors without cause.  You can measure the voltage at the output terminals;  it should ideally be set to 27.1V – 27.3V.

The “Logic Power” Chain

In a typical KRC2 Ed05 setup, the components you’ve asked about work like this:

PH1003-2840: Provides 27V DC power to the whole system.2

DSE-IBS: Uses that power to run its processor and send commands.

KSD1-08: Receives commands from the DSE and pulls high-voltage power (from the KPS600) to move the motor.

KUKA MFC2 Multi-Functional Control Board

Technical Specifications

Compatibility: Supports KUKA KRC2 and later controller generations.

Feedback Support: Compatible with resolvers, incremental encoders, and absolute encoders (e.g., Hiperface, EnDat, SFD-M).

Input/Output:

Input sensitivity: Adjustable (1.0mV/V, 2.0mV/V, 3.0mV/V).

Input impedance: ≥10 MΩ.

Sampling rate: 100 kHz for high-speed data acquisition.

Power Requirements:

Operates with 240V AC power supply (standard industrial voltage).

Environmental Resistance:

Designed for industrial settings with robust shielding against electromagnetic interference (EMI) and radio-frequency interference (RFI).

Physical Attributes:

Silver-white color, compact form factor for cabinet or DIN rail mounting.

MFC2

Key Features

High-Precision Control: Enables sub-micron positioning accuracy with low-latency feedback processing.

Multi-Axis Synchronization: Manages up to 8 axes simultaneously, critical for complex robotic tasks.

Flexible Feedback Integration: Supports a wide range of encoder types, eliminating the need for additional signal converters.

Real-Time Diagnostics: Built-in LED indicators for system status monitoring and error alerts.

Industrial-Grade Design: Metal enclosure ensures durability in harsh environments, with optional IP65 rating for dust/water resistance.

Functionality

MFC2

Motion Control: Regulates torque, velocity, and position loops for servo motors (e.g., KUKA AKM series).

Signal Conversion: Converts low-level encoder signals into digital data for the main controller.

Error Handling: Monitors overcurrent, overvoltage, and overtemperature conditions to protect hardware.

Network Communication: Integrates with CANopen or optional EtherCAT for distributed control architectures.

Application Scenarios

Industrial Robotics: Powers joints and actuators in KUKA’s 6-axis robots (e.g., KR AGILUS series) for tasks like welding, material handling, and assembly.

CNC Machinery: Controls feed axes and spindles in machining centers, lathes, and milling machines.

Packaging Systems: Drives conveyor belts, sealing units, and labeling machines in high-speed packaging lines.

Semiconductor Manufacturing: Facilitates nanometer-level positioning in wafer handling and inspection equipment.

Automotive Testing: Manages test benches for engine, transmission, and chassis validation.

Medical Devices: Powers surgical robots and imaging systems requiring stable, precise motion.

The Kuka KSD1-48 is a specialized servo drive controller that is capable of functioning efficiently in environments with temperatures between 0 and 40 degrees Celsius.

It provides a flexible input voltage range that spans from 0 to 585 V.

The input current is rated at 20.8 A, allowing it to handle substantial load demands effectively.

This drive controller delivers an output voltage range of up to 480 V.

It can output a maximum current of 17 A, making it suitable for various applications requiring reliable power delivery.

With a power rating set at 1 kVA, the KSD1-48 is designed to support robust performance in motion control tasks.

It operates at an output frequency ranging from 0 to 480 Hz, catering to different operational needs.

KSD1-48

Manufactured by Kuka, this controller is built on the Roboter GmbH platform, which signifies its robust design for automation solutions.   Its dimensions are compact at 132 x 240 x 180 mm, which aids in installation flexibility.

Weighing just 1.44 kg, this unit is lightweight enough to integrate into various setups without adding significant bulk.   Overall, the KSD1-48 serves as a reliable option in advanced control systems.

KSD1-48

Manufacturer    Kuka

Product Line    KRC2

Part Number    KSD1-48

Weight    20.00 lbs (9.07 kg)

Product    Servo Drive Controller

Ambient Operating Temperature Range    0 to 40 degrees Celsius

Input Voltage    0 to 585 V

Input Current    20.8 A

Output Voltage    0 to 480 V

Output Current    17 A

Power Rating    1 kVA

Output Frequency    0 to 480 Hz

Controller Platform    Roboter GmbH

KUKA KSD1-16 Overview

KUKA KSD1-16 Robotics Servo Drive

The KUKA KSD1-16 Robotics Servo Drive is a cutting-edge solution designed for industrial robots.

It delivers precise control and reliable performance in demanding automation applications.

This servo drive is engineered to manage eight amps and operates at 0-480VAC, making it ideal for a wide range of robotic systems.  With its advanced technology and compatibility with KUKA robotics, the KSD1-16 ensures seamless operation and optimized efficiency, meeting the rigorous demands of modern industrial environments.

Exceptional Control and Performance

The KSD1-16 servo drive offers unparalleled precision in motor control, enabling smooth and accurate movements for robotic arms and other components.

It provides consistent power delivery and adaptive performance, ensuring robots can handle complex tasks efficiently and reliably.

This makes it suitable for applications ranging from assembly lines to intricate manufacturing processes, where precision and speed are critical.

Designed for Robust Industrial Use

Built to withstand harsh industrial conditions, the KUKA KSD1-16 features durable construction and advanced thermal management systems.  These ensure stable performance even under continuous operation in high-demand environments.

Its compatibility with 0-480VAC power input further enhances its versatility, allowing it to be integrated into diverse setups without compromising efficiency.

Seamless Integration with KUKA Robots

The KSD1-16 is optimized for KUKA robotic systems, making integration straightforward and hassle-free.  This servo drive is a perfect match for users looking to enhance the performance of their robotic systems with minimal configuration.

Its compact design facilitates easy installation, while its robust performance improves robots’ operational capabilities, enabling them to perform complex, high-precision tasks.

The KSD1-08 is a member of the KUKA Servo Drive (KSD) family,

specifically designed for use in the KRC2 and VKRC2 robot controllers.

Technical Specifications

The “08” in the name refers to the drive’s current rating.  It is a Size 1 (BG1) module, the smallest in the series, typically used for the smaller axes of a robot (Axes 4. 5. and 6) or for small external axes.

Feature    Specification

Input Voltage    565 – 675 V DC (from the KPS 600)

Output Current    8 Amps (Peak/Acceleration)

Rated Current    ~4 Amps (Continuous)

Control Method    Field-oriented vector control

Cooling    Forced air (internal heat sink)

Part Numbers    00-105-925. 00-122-284. or 00-116-415

How it Connects

The KSD1-08 sits in a “drive bus” inside the KRC2 cabinet.  It has three main connection points:

DC Bus (Top/Back): Connects to the KPS 600 (Power Supply) to get high-voltage DC power.

Interbus (Front/Bottom): A small ribbon cable or data connector that links all KSDs back to the DSE-IBS card.

Motor Output (Bottom): The heavy-duty cable that goes out to the robot’s junction box and eventually to the motor.

Troubleshooting Common Failures

KSD1-08

If a KSD1-08 fails, the robot will usually drop “Drives Off” and display a message like “Output stage error” or “General Servo Error.”

KSD1-08

LED Indicators: Look at the front of the module.

Green: Drive is healthy and ready.

Red: Internal fault (Overcurrent, short circuit, or overtemperature).

Dark: No power from the DC bus or a blown internal fuse.

Swapping for Diagnostics: Since KRC2 robots often have multiple KSD1-08 units (for axes 4. 5. and 6), you can swap two identical modules to see if the error “follows” the hardware.

Note: You must update the Interbus address or robot configuration if you move modules permanently.

Heat Sink Clogging: These units are prone to overheating if the cabinet filters are not cleaned, as dust builds up in the cooling fins behind the module.

Comparison with Other KSDs

Model    Current Rating    Typical Use

KSD1-08    8A    Small axes (A4-A6)

KSD1-16    16A    Medium axes or high-torque wrist axes

KSD1-32    32A    Large axes (A1-A3)

KSD1-48/64    48A / 64A    Heavy-duty axes on large robots (KR500+)

The KRC2 and VKRC2 are two versions of the same hardware platform, but they are tailored for very different operational environments.

While the “K” stands for KUKA, the “V” in VKRC2 stands for Volkswagen, as this version was specifically developed for the VW Group and its subsidiaries (Audi, SEAT, Skoda).

Comparison at a Glance

Feature    KRC2 (Standard)    VKRC2 (VW Standard)

Primary User    General Industrial Market    VW Group / Automotive Tier 1

Software    KUKA System Software (KSS)    VW System Software (VSS)

Programming    KRL (KUKA Robot Language)    Inline forms / “Folge” & “Up”

Flexibility    High (Open programming)    Low (Locked to standards)

Ease of Use    Requires training in KRL    Designed for rapid deployment

Key Differences

1. Programming Philosophy

KRC2 (KRL): This is the “open” version. A programmer has full access to the KUKA Robot Language (KRL). You can create complex custom logic, use variables freely, and build highly specialized functions.

VKRC2 (Structured): This is “menu-driven.” To maintain consistency across thousands of robots in a VW factory, programming is restricted to a specific structure:

Folge (Sequence): The main program sequence.

Up (Subroutine): Smaller motion sub-programs.

Makro: Logic-only routines (no motion).

Note: In VKRC2. you generally cannot type free-form code unless you enter “Expert Mode” with a special key/password.

KRC2/VKRC2

2. User Interface

The KCP (KUKA Control Panel) looks identical for both, but the soft-keys and menus are different.

VKRC2 menus focus on automotive-specific tasks like “Spot Welding” or “Gripper Control” using standardized blocks.

KRC2 menus are more general, allowing you to configure various types of industrial fieldbuses and custom kinematic systems more easily.

3. Interbus & Hardware

Because of its automotive roots, the VKRC2 almost always includes the DSE-IBS (Interbus) card you asked about previously, as Interbus was the VW group standard for years. While standard KRC2 units often use it, they are more frequently found with DeviceNet, Profibus, or Ethernet/IP depending on the customer’s factory.

4. Safety & Interfacing

VKRC2 often uses a specific “VW Interface” (X11/X40 connectors) designed to plug directly into the standard VW cell safety PLC.

KRC2 uses the standard X11 interface which is more “universal” for integration into diverse factory environments.

Can you convert a VKRC2 to a KRC2?

Yes, it is a common practice in the used robot market. Since the hardware (PC, drives, motors) is nearly identical, you can “reflash” a VKRC2 to run standard KSS software.

Requirement: You need a standard KSS software installation (e.g., V5.x) and potentially a change in some wiring jumpers on the MFC/ESC safety cards.

Kuka KPS-600/20-ESC Power Supply Unit

KPS-600-20-ESC by Kuka is in the KPS Power Supply Family.     KPS Power Supplies power multiple drives and servos.

This KPS-600-20-REL offers a Rated Input Power of AC400/415V and Rated Input Current of 15A.

It also features a Rated Output Power of DC565/585V and a Rated Output Current of 20A with a Weight of 6.5 lbs.

KUKA KPS600-20-ESC Robotics Power Supply

Product Overview

The KUKA KPS600-20-ESC is an advanced robotics power supply module designed for precision industrial automation systems.

Operating at 400–480 VAC, 50/60 Hz, this power supply ensures stable and reliable performance in demanding environments.

Featuring status LEDs, dual Ethernet ports, and screw terminals, the unit offers precise diagnostics, easy integration, and secure connectivity.

Although discontinued by the manufacturer, the KPS600-20-ESC remains a critical component in many existing KUKA robotics systems, providing consistent and dependable performance.

Technical Specifications

KPS-600/20-ESC

Part Number: KPS600-20-ESC (00-134-525)

Manufacturer: KUKA

Category: Servo Drive / Robotics Power Supply

Input Voltage: 400–480 VAC

Frequency: 50/60 Hz

Connectivity: Dual Ethernet ports

Indicators: Status LEDs

Terminals: Screw terminals

KPS-600/20-ESC

Key Features

Robotics Power Supply: Optimized for KUKA automation systems.

High Voltage Range: Supports 400–480 VAC for global compatibility.

Precise Monitoring: Equipped with status LEDs for fast system diagnostics.

Dual Ethernet Ports: Ensures reliable communication and integration.

Secure Installation: Screw terminals provide strong and stable connections.

Applications

The KUKA KPS600-20-ESC is designed for use in:

Industrial robotics power systems

Factory automation setups

Precision manufacturing cells

Legacy KUKA robotic applications requiring specific servo drive modules

Manufacturer : KUKA

Product No. : 00-130-547

Product Type : Teach Pendant Controller KCP2

10m cable

8″ color display (VGA resolution, 640 x 480)

Universal application : All KUKA robots running on KSS and Sunrise.OS can be operated in the desired language using the KUKA smartPAD.

Ergonomic 6D mouse : Offers intuitive jogging and reorientation of the robot in three or six degrees of freedom.

Integrated protectors : Integrated protectors offer the greatest possible protection in the event of falling.

Simple data transmission : Two easily accessible USB ports enable direct saving and loading of application programs and connection of other supported USB devices.

Efficient operation : Inputs are made quickly and easily via a brilliant, capacitive touch display.

Maintenance-friendly design : A service flap enables simple exchange of the cable as required.

00-130-547

Parameter

Main Parameters

Value/Description

Product Model

KCP2

Manufacturer

KUKA

Product Category

Teach Pendant Control Panel

00-130-547

Operating Voltage

Operates on 24 V DC power, ensuring stable and reliable power supply.

Rated Current

Has a rated current of 0.5 A, consuming power efficiently during operation.

Weight

Weighs approximately 7 lbs (about 3.2 kg), making it lightweight and easy to handle for operators.

Dimensions

Compact design with dimensions of approximately 310 mm (length) x 215 mm (width) x 110 mm (height), suitable for both desktop and handheld use.

Display

Features an 8.4 – inch TFT color touchscreen with a resolution of 800 x 600 pixels, providing clear and detailed visual feedback.

Storage

Equipped with 128 MB of memory and 1 GB of flash storage, allowing for the storage of programs, data, and configurations.

Interfaces

Comes with 2 USB interfaces for easy connection of external devices such as USB drives for data transfer. It also has 1 Ethernet interface for network connectivity, enabling seamless communication with other components in the industrial network.

Operating Temperature Range

Can operate within a temperature range of 0 °C to 45 °C, suitable for a wide range of industrial environments.

Protection Class

Has an IP54 protection class, providing protection against dust and water splashes, ensuring durability in harsh industrial settings.

KUKA E93DE143-4B531LP Robot control module

Place of Origin:Germany

Order Number:E93DE143-4B531LP

Brand:KUKA

Model:E93DE143-4B531LP

Operating Voltage:220 V

Output Frequency:50 kHz

Certified Product:CE, RoHS

Series:E93DE143-4B531LP

Material Coding:E93DE143-4B531LP

E93DE143-4B531LP

The KUKA E93DE143-4B531LP is engineered for seamless integration into existing industrial systems, offering unparalleled precision and reliability. Its advanced design ensures consistent performance across a wide range of applications.

E93DE143-4B531LP

This module is built with high-quality materials to withstand harsh industrial environments. The robust construction guarantees long-lasting performance and minimal downtime.

With a certified product status, users can trust that the E93DE143-4B531LP meets stringent quality standards and regulatory requirements. It is ideal for use in manufacturing, automation, and other industrial processes.

The E93DE143-4B531LP is designed for easy installation and maintenance, reducing setup time and operational costs. Its user-friendly interface allows for quick configuration and troubleshooting.

Backed by KUKA’s reputation for excellence in industrial automation, this module delivers superior functionality and value. Whether you are upgrading an existing system or building a new one, the E93DE143-4B531LP is a smart choice.

The KUKA DSE-IBS 3.02 is a critical electronic component found in older KUKA robot controllers, specifically the KRC2 (and some late KRC1) generations.

1 It is a “Digital Servo Electronic” (DSE) card integrated with an “Interbus” (IBS) master.

In short, it is the “brain” that translates high-level commands from the controller’s PC into the precise electrical signals that move the robot’s motors.

Technical Overview

The board typically works in tandem with the MFC (Multi-Function Card). Together, they handle the real-time communication between the robot’s Windows-based software and the power electronics (drives/servos).

Feature    Description

Model    DSE-IBS 3.02

Part Number    Commonly associated with 00-108-766 or 00-117-336

Compatibility    KUKA KRC2. KRC2 Edition 2005 controllers

Function    Digital servo control and Interbus master interface

Weight    Approx. 0.1 – 0.2 kg

DSE-IBS 3.02

Key Responsibilities

Path Calculation: It receives setpoint values from the main CPU and calculates the precise motion for each axis.

Feedback Loop: It processes data from the motor encoders (resolvers) to ensure the robot is exactly where it’s supposed to be.

I/O Communication: The “IBS” portion acts as the master for the Interbus system, allowing the robot to communicate with external sensors, grippers, and tools.

Safety Sync: It helps monitor the safety circuit (ESC) to ensure the robot stops immediately if a gate is opened or an E-stop is pressed.2

DSE-IBS 3.02

Common Issues & Troubleshooting

If this board fails, the robot will typically not move at all. Common error messages on the KCP (KUKA Control Panel) include:

“DSE-IBS Communication Error”

“Error in DSE-No. 1”

“Ackn. Interbus error”

Troubleshooting Steps:

Reseat the Card: These cards are PCI/ISA-based. Sometimes vibration causes them to sit loosely. Power down, remove, and firmly reseat the card.

Check the LED Status: The card usually has onboard LEDs. If they are solid red or completely dark during operation, the hardware may be defective.

Cable Check: Ensure the Interbus cable (connected to the front of the board) is secure and not frayed.

Battery Health: If the controller’s UPS batteries are dead, the DSE might lose its configuration data upon a hard reboot.