KUKA KPS Series Power Supply Units

Technical Dossier

Product Details And Specifications

KUKA KPS Series: Comprehensive Module Range and Technical Overview

The KUKA KPS (Cabinet Power Supply) series is the primary power distribution and conditioning backbone for KUKA robot controller cabinets, deployed across heavy industrial sectors including automotive body-in-white assembly, chemical processing plants, nuclear facility material handling, and petroleum refinery automation. KPS units are integrated into KUKA KR C1, KR C2, KR C3, and KR C4 controller generations, making them one of the most widely installed robot controller power supply families in global manufacturing. Installed base estimates place KPS-series units in hundreds of thousands of robot cells worldwide, with active deployments spanning production lines commissioned as early as the mid-1990s through current-generation facilities.

The Evolution of KPS Series Architecture

The KPS series underwent several distinct architectural generations aligned with KUKA's controller platform transitions. Early KPS units designed for the KR C1 platform (introduced circa 1996) operated on a discrete analog regulation architecture with limited diagnostic output. The KR C2 era (2000–2010) introduced the KPS-600 family, including the KPS-600/20-REL, which added relay-monitored safety outputs and improved EMC shielding for compliance with EN 60204-1. The KR C3 and KR C4 transitions brought digitally supervised power rails with EtherCAT-compatible diagnostic interfaces, represented by the KPS-27/20 and KPS-54/6 sub-families.

Compatibility across generations is not plug-and-play. KR C1 KPS units use a proprietary 64-pin backplane connector incompatible with KR C2 cabinets. KR C2 KPS units share a common form factor but differ in firmware handshake protocols from KR C4 equivalents. Sourcing the correct generation is mandatory for safe integration. DriveKNMS maintains cross-reference tables for all known KPS variants.

KPS Series Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly deployed models within the KUKA KPS power supply series. Units are categorized by function and controller generation compatibility.

Primary Cabinet Power Supplies (KR C2 / KR C3 Compatible)

• KPS-600/20-REL: 600W cabinet PSU with relay-monitored safety output, KR C2 primary
• KPS-600/20: 600W cabinet PSU, standard variant without relay monitoring output
• KPS-600/10: 600W PSU, 10A output rail, reduced-load KR C2 configurations
• KPS-27/20: 27V / 20A regulated supply for KR C4 controller auxiliary bus
• KPS-54/6: 54V / 6A supply for KR C4 drive bus pre-charge circuit
• KPS-27/40: 27V / 40A high-current variant for multi-axis KR C4 cabinets
• KPS-600/20-NR: 600W PSU, non-relay variant, KR C2 retrofit applications

Auxiliary and Logic Power Supplies

• KPS-15/6: 15V / 6A logic supply for KR C1 controller internal bus
• KPS-24/10: 24V / 10A auxiliary supply for I/O interface boards
• KPS-24/20: 24V / 20A auxiliary supply, extended I/O configurations
• KPS-48/10: 48V / 10A intermediate bus supply for servo pre-charge

Regenerative and Braking Supply Variants

• KPS-600/20-BR: 600W PSU with integrated braking resistor interface
• KPS-600/40: 600W / 40A high-current variant for heavy-payload robot cabinets
• KPS-1200/20: 1200W dual-rail supply for tandem or extended-reach robot systems
• KPS-1200/40: 1200W / 40A supply for multi-robot shared cabinet configurations
• KPS-600/20-UPS: 600W PSU with integrated UPS buffer for controlled shutdown sequences

Sourcing Hard-to-Find & Obsolete KPS Series Parts

The KR C1 and early KR C2 KPS variants have been officially discontinued by KUKA AG. OEM lead times for remaining new-old-stock units are indeterminate, and factory repair services for pre-2005 KPS hardware are no longer offered through standard KUKA service channels. DriveKNMS maintains a dedicated inventory of tested, refurbished, and new-surplus KPS units specifically to support lifecycle extension for these platforms.

For facilities operating KR C2-era robot cells with no near-term plans for controller modernization, DriveKNMS provides: verified functional units with 12-month operational warranty, serialized traceability documentation, and cross-reference support for identifying equivalent replacement units where direct replacements are unavailable. Requests for obsolete KPS models are processed within 24 hours. Multi-unit procurement for planned maintenance shutdowns is supported with volume pricing.

Quality Control for the KPS Series Range

KPS units present specific test challenges due to their integrated relay safety circuits, multi-rail output architecture, and sensitivity to input voltage transients. DriveKNMS applies the following test protocol to all KPS units prior to dispatch:

• Input voltage sweep test: 3-phase 380–480VAC ±10%, verifying regulation stability across the full input tolerance band
• Output rail load test: each DC output rail loaded to 100% rated current for a minimum 2-hour burn-in period
• Relay contact integrity test: safety relay contacts verified for actuation voltage, hold voltage, and contact resistance per IEC 61810-1
• Thermal imaging: infrared scan of all power semiconductors and transformer windings under full load to identify latent thermal failures
• Backplane connector inspection: all connector pins inspected for fretting corrosion, a known failure mode in KPS units with high vibration exposure
• Firmware version verification: where applicable, firmware revision is logged and matched to controller compatibility matrix