KUKA KRC5 Modules: 00-320-104 / 00-291-556 SmartPAD Teach Pendant –

Technical Dossier

Product Details And Specifications

KUKA KRC5 Series: Comprehensive Module Range and Technical Overview

The KUKA KRC5 (KUKA Robot Controller 5) is the fifth-generation robot controller platform from KUKA Robotics, deployed across heavy industrial sectors including automotive body-in-white assembly, chemical processing plants, nuclear facility maintenance, and petroleum refinery automation. As of 2026, the KRC5 represents KUKA's current production standard, replacing the KRC4 across all new robot shipments globally. Its modular architecture — separating the controller cabinet, safety logic, fieldbus communication, and the operator interface (SmartPAD) — makes it the reference platform for integrators requiring IEC 61508 SIL 2 functional safety compliance in continuous-process environments.

The KRC5 controller family supports KUKA's full robot range: KR AGILUS, KR CYBERTECH, KR QUANTEC, KR FORTEC, and KR IONTEC series, with payload capacities from 6 kg to 1,000 kg. The controller communicates via KUKA.ProfiNet, KUKA.EtherNet/IP, KUKA.DeviceNet, and KUKA.PROFIBUS fieldbus packages, enabling direct integration into Siemens TIA Portal, Rockwell Studio 5000, and ABB 800xA DCS environments.

The Evolution of KRC5 Architecture

KUKA's controller architecture has evolved through five distinct generations since the introduction of the KRC1 in the mid-1990s. The KRC1 and KRC2 used proprietary VxWorks-based real-time operating systems with DSE (Digital Servo Electronics) boards and were limited to RS-232 and DeviceNet communication. The KRC4 (introduced circa 2010) marked the transition to a Windows Embedded Standard 7 host OS running KUKA System Software (KSS) 8.x, with a dedicated VxWorks real-time kernel for motion control — a dual-OS architecture that became the industry benchmark.

The KRC5 (introduced 2021) retains the dual-OS philosophy but migrates to a 64-bit Intel architecture host, running KSS 8.7+ on Windows 10 IoT Enterprise LTSC. Key architectural changes include: integrated safety controller (replacing the external KSM module of KRC4), native OPC UA server, and a redesigned SmartPAD-2 operator panel (part numbers 00-320-104 and 00-291-556) with a capacitive touchscreen replacing the resistive display of the KRC4 SmartPAD. Backward compatibility with KRC4 KUKA.WorkVisual projects requires migration via WorkVisual 6.0+. KRC2 programs require full recompilation and are not binary-compatible.

For installations where KRC4 and KRC5 controllers coexist on the same production line, KUKA provides the KUKA.OfficeLite simulation environment to validate program migration before live deployment.

KRC5 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified components within the KUKA KRC5 ecosystem, classified by functional category:

Operator Interface / Teach Pendant

• 00-320-104: SmartPAD-2 teach pendant assembly, capacitive touch, KRC5 native, with 6m cable
• 00-291-556: SmartPAD-2 variant / sub-assembly reference, paired with 00-320-104 in KRC5 configurations
• 00-168-334: SmartPAD (KRC4 generation) teach pendant — predecessor unit, resistive touch
• 00-232-430: SmartPAD cable assembly, 10m extension, KRC4/KRC5 compatible

Controller Cabinet / CPU & Computing Modules

• 00-317-346: KRC5 main computer board (KPC5), Intel-based, KSS 8.7 pre-installed
• 00-317-347: KPC5 variant with extended RAM configuration for high-axis-count applications
• 00-311-564: KRC5 compact controller unit (KRC5 micro), for KR AGILUS small robots
• 00-311-565: KRC5 micro controller, extended I/O variant

Safety & Drive Modules

• 00-317-350: KRC5 integrated safety controller module (replaces KRC4 KSM)
• 00-317-351: Safety interface board, SIL 2 certified, KRC5 cabinet
• 00-311-570: KRC5 servo drive module, 3-axis, 400V AC input
• 00-311-571: KRC5 servo drive module, 6-axis, 400V AC input

Power Supply Modules

• 00-317-355: KRC5 primary power supply unit, 400V/3-phase, 16A
• 00-317-356: KRC5 24VDC auxiliary power supply module
• 00-311-580: KRC5 micro power supply, single-phase 230V input

Communication & Fieldbus Adapters

• 00-317-360: KUKA.ProfiNet IO adapter, KRC5 cabinet-mount
• 00-317-361: KUKA.EtherNet/IP adapter module, KRC5
• 00-317-362: KUKA.DeviceNet master/slave adapter, KRC5

Sourcing Hard-to-Find & Obsolete KRC5 Parts

Although the KRC5 is KUKA's current production platform, specific sub-assemblies — including early-production SmartPAD-2 units (00-320-104, 00-291-556), first-generation KPC5 boards (00-317-346), and initial-run servo drive modules — have experienced allocation constraints due to global semiconductor supply chain disruptions. DriveKNMS maintains a dedicated inventory of KRC5 components sourced through authorized distribution channels and verified secondary market suppliers.

For installations where KRC4 controllers remain in service alongside KRC5 units, DriveKNMS also stocks KRC4 legacy components including SmartPAD (00-168-334), KSM safety modules, and KRC4 servo packs — providing a single-source procurement solution for mixed-generation robot fleets. All sourced units are accompanied by full traceability documentation including batch records and, where applicable, original KUKA factory test certificates.

Quality Control for the KRC5 Range

KRC5 modules present specific test challenges due to the integrated safety architecture and high-speed EtherCAT backplane communication between the KPC5 computer, servo drives, and safety controller. DriveKNMS applies the following verification protocol to all KRC5 units processed:

• SmartPAD-2 (00-320-104 / 00-291-556): Full capacitive touch calibration, enable switch (deadman) cycle test (minimum 500 actuations), emergency stop circuit continuity verification per ISO 13850, display pixel uniformity check, and KSS 8.7 firmware handshake validation via KRC5 test rig.
• KPC5 Computer Boards: 72-hour burn-in under simulated KSS load, memory integrity test (MemTest86+), SSD health check (S.M.A.R.T. data review), and EtherCAT master communication verification.
• Servo Drive Modules: AC input voltage sweep (360–440V), phase balance verification, IGBT gate drive signal oscilloscope check, and thermal imaging under 80% rated load for 30 minutes.
• Safety Modules: Dual-channel input verification, SIL 2 response time measurement, and cross-circuit fault injection test per IEC 62061.

All tested units are issued a DriveKNMS inspection report with pass/fail criteria documented per module type.