KUKA KR C4 Operating Instructions
KUKA KR C4 Operating Instructions
KUKA KR C4 Operating Instructions
KR C4; KR C4 CK
Operating Instructions
Issued: 26.01.2015
Version: BA KR C4 GI V11
KR C4; KR C4 CK
© Copyright 2015
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties
without the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user
has no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis,
how-ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
1 Introduction .................................................................................................. 9
1.1 Industrial robot documentation ................................................................................... 9
1.2 Representation of warnings and notes ...................................................................... 9
1.3 Trademarks ................................................................................................................ 9
1.4 Terms used ................................................................................................................ 10
2 Purpose ........................................................................................................ 13
2.1 Target group .............................................................................................................. 13
2.2 Intended use .............................................................................................................. 13
3 Product description ..................................................................................... 15
3.1 Overview of the industrial robot ................................................................................. 15
3.2 Overview of the robot controller ................................................................................. 15
3.3 KUKA Power Pack ..................................................................................................... 17
3.4 KUKA Servo Pack ...................................................................................................... 17
3.5 Control PC ................................................................................................................. 17
3.6 Cabinet Control Unit ................................................................................................... 18
3.7 Safety Interface Board ............................................................................................... 19
3.8 Resolver Digital Converter ......................................................................................... 19
3.9 Controller System Panel ............................................................................................ 20
3.10 Low-voltage power supply unit ................................................................................... 21
3.11 24 V external power supply ........................................................................................ 21
3.12 Batteries ..................................................................................................................... 21
3.13 Mains filter .................................................................................................................. 21
3.14 Bus devices ................................................................................................................ 21
3.14.1 KCB devices ......................................................................................................... 22
3.14.2 KSB devices and configuration variants ............................................................... 22
3.14.3 KEB devices and configuration variants ............................................................... 22
3.15 Connection panel interfaces ...................................................................................... 24
3.16 Motor connector Xxx, external axes X7.1, X7.2, X7.3 ............................................... 26
3.16.1 Connector pin allocation, motor connector X20 .................................................... 27
3.16.2 Connector pin allocation for motor connector X20 with 1 KPP and 1 KSP ........... 28
3.16.3 Connector pin allocation X20.1 and X20.4 (heavy-duty robot) ............................. 29
3.16.4 Connector pin allocation X7.1 for external axis 1 ................................................. 30
3.16.5 Connector pin allocation X7.1 and X7.2 for external axes 1 and 2 ....................... 30
3.16.6 Connector pin allocation X7.1, X7.2 and X7.3 for external axes 1, 2 and 3 ......... 31
3.16.7 Connector pin allocation X8 (heavy-duty palletizing robot) (4 axes) ..................... 32
3.16.8 Connector pin allocation X20 (palletizing robot) (4 axes) ..................................... 33
3.16.9 Connector pin allocation X20.1 and X20.4 (heavy-duty palletizing robot) (5 axes) 34
3.16.10 Connector pin allocation X20 (palletizing robot) (5 axes) ..................................... 35
3.16.11 Connector pin allocation X81 (4 axes) .................................................................. 36
3.16.12 Connector pin allocation X82 (8 axes) .................................................................. 37
3.16.13 Connector pin allocation X7.1 for palletizing robot, external axis 1 ...................... 37
3.16.14 Connector pin allocation X7.1 and X7.2 for palletizing robot, for external axes 1 and 2 38
3.17 Multiple connector X81, single connectors X7.1 to X7.4 ............................................ 38
3.17.1 Connector pin allocation X81 (3 axes) .................................................................. 39
3.17.2 Connector pin allocation X81 (4 axes) .................................................................. 40
3.17.4 Connector pin allocation X81, X7.1 and X7.2 (6 axes) ......................................... 42
3.17.5 Connector pin allocation X81, X7.1 to X7.3 (7 axes) ............................................ 43
3.17.6 Connector pin allocation X81, X7.1 to X7.4 (8 axes) ............................................ 44
3.18 Single connectors X7.1 to X7.8 ................................................................................. 46
3.18.1 Connector pin allocation X7.1 to X7.3 (3 axes) .................................................... 47
3.18.2 Connector pin allocation X7.1 to X7.4 (4 axes) .................................................... 48
3.18.3 Connector pin allocation X7.1 to X7.5 (5 axes) .................................................... 49
3.18.4 Connector pin allocation X7.1 to X7.6 (6 axes) .................................................... 50
3.18.5 Connector pin allocation X7.1 to X7.7 (7 axes) .................................................... 52
3.18.6 Connector pin allocation X7.1 to X7.8 (8 axes) .................................................... 54
3.19 Control PC interfaces ................................................................................................ 55
3.19.1 Motherboard D2608-K interfaces ......................................................................... 56
3.19.2 Motherboard D3076-K interfaces ......................................................................... 57
3.19.3 Motherboard D3236-K interfaces ......................................................................... 58
3.20 KUKA smartPAD holder (optional) ............................................................................ 59
3.21 Set of rollers (optional) .............................................................................................. 60
3.22 Cabinet cooling .......................................................................................................... 60
3.23 Description of the space for integration of customer options ..................................... 61
4 Technical data .............................................................................................. 63
4.1 External 24 V power supply ....................................................................................... 65
4.2 Safety Interface Board ............................................................................................... 65
4.3 Dimensions of robot controller ................................................................................... 66
4.4 Minimum clearances, robot controller ........................................................................ 67
4.5 Swing range for cabinet door ..................................................................................... 68
4.6 Dimensions of the smartPAD holder (optional) ......................................................... 68
4.7 Dimensions of boreholes for floor mounting .............................................................. 69
4.8 Dimensions of boreholes for technology cabinet ....................................................... 69
4.9 Plates and labels ....................................................................................................... 69
5 Safety ............................................................................................................ 73
5.1 General ...................................................................................................................... 73
5.1.1 Liability ................................................................................................................. 73
5.1.2 Intended use of the industrial robot ...................................................................... 73
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 74
5.1.4 Terms used .......................................................................................................... 74
5.2 Personnel .................................................................................................................. 76
5.3 Workspace, safety zone and danger zone ................................................................ 77
5.3.1 Determining stopping distances ........................................................................... 77
5.4 Triggers for stop reactions ......................................................................................... 78
5.5 Safety functions ......................................................................................................... 78
5.5.1 Overview of the safety functions ........................................................................... 78
5.5.2 Safety controller ................................................................................................... 79
5.5.3 Mode selection ..................................................................................................... 79
5.5.4 “Operator safety” signal ........................................................................................ 80
5.5.5 EMERGENCY STOP device ................................................................................ 80
5.5.6 Logging off from the higher-level safety controller ................................................ 81
5.5.7 External EMERGENCY STOP device .................................................................. 81
7 Transportation.....................................................................................................125
7.1 Transportation using lifting tackle........................................................................................125
7.2 Transportation by fork lift truck.............................................................................................126
7.3 Transportation by pallet truck............................................................................................... 128
7.4 Transportation with the set of rollers (optional)....................................................................129
9 Operation.............................................................................................................139
9.1 KUKA smartPAD teach pendant.......................................................................................... 139
9.1.1 Front view....................................................................................................................... 139
9.1.2 Rear view....................................................................................................................... 141
10 Maintenance.........................................................................................................143
10.1 Maintenance symbols.......................................................................................................... 143
10.2 Checking SIB relay outputs.................................................................................................. 145
10.3 Checking Extended SIB relay outputs.................................................................................145
10.4 Cleaning the robot controller................................................................................................ 146
11 Repair................................................................................................................... 147
11.1 Repair and procurement of spare parts...............................................................................147
11.2 Wiring example X11............................................................................................................. 148
11.3 Exchanging the external fan................................................................................................ 149
11.4 Exchanging the internal fan.................................................................................................150
11.5 Exchanging control PC components....................................................................................151
11.5.1 Exchanging the control PC.............................................................................................151
11.5.2 Exchanging the control PC fan.......................................................................................152
11.5.3 Exchanging the motherboard.........................................................................................154
11.5.4 Exchanging the motherboard battery.............................................................................154
11.5.5 Exchanging the LAN Dual NIC network card..................................................................154
11.5.6 Exchanging the hard drive..............................................................................................155
11.6 Modifying the system configuration, exchanging devices....................................................156
11.6.1 Exchanging the KUKA Power Pack................................................................................157
11.6.2 Exchanging the KUKA Servo Pack.................................................................................160
12 Troubleshooting.................................................................................................. 177
12.1 Cabinet Control Unit LED display........................................................................................ 177
12.2 Cabinet Control Unit fusing.................................................................................................. 181
12.3 Resolver Digital Converter LED display..............................................................................182
12.4 Controller System Panel LED display.................................................................................. 183
12.4.1 Controller System Panel LED error display....................................................................185
12.5 Control PC interfaces.......................................................................................................... 185
12.5.1 LAN Onboard LED display on motherboard D2608-K....................................................186
12.5.2 LAN Onboard LED display on motherboard D3076-K....................................................186
12.5.3 LAN Onboard LED display on motherboard D3236-K....................................................187
12.6 Safety Interface Board LED display..................................................................................... 188
12.7 Safety Interface Board fuses................................................................................................ 191
12.8 Checking the KUKA Servo Pack.........................................................................................193
12.9 Checking the KUKA Power Pack.........................................................................................194
12.10 Checking the KUKA Power Pack 3.....................................................................................196
12.11 KPP and KSP error messages............................................................................................196
12.12 KPP and KSP warning messages.......................................................................................200
Index..................................................................................................................... 215
1 Introduction
information.
1.3 Trademarks
Windows is a trademark of Microsoft Corporation.
is a trademark of ODVA.
Term Description
Br M{Number} Brake Motor{Number}
CCU Cabinet Control Unit
CIB Cabinet Interface Board
CIP Safety Common Industrial Protocol Safety
CIP Safety is an Ethernet/IP-based safety inter-
face for connecting a safety PLC to the robot
controller. (PLC = master, robot controller =
slave)
CK Customer-built Kinematics
CSP Controller System Panel
Display element and connection point for USB
and network
Dual NIC Dual Network Interface Card
Dual-port network card
EDS Electronic Data Storage (memory card)
EDS cool Electronic Data Storage (memory card) with
extended temperature range
EMD Electronic Mastering Device
EMC ElectroMagnetic Compatibility
Ethernet/IP Ethernet/Internet Protocol is an Ethernet-based
field bus.
HMI Human Machine Interface:
KUKA.HMI is the KUKA user interface.
KCB KUKA Controller Bus
KEB KUKA Extension Bus
KLI KUKA Line Interface
Connection to higher-level control infrastructure
(PLC, archiving)
KOI KUKA Operator Panel Interface
KONI KUKA Option Network Interface
Interface for KUKA options
KPC KUKA control PC
KPP KUKA Power Pack
Drive power supply with drive controller
KRL KUKA Robot Language
KUKA programming language
KSB KUKA System Bus
A field bus for internal networking of the control-
lers
KSI KUKA Service Interface
Interface on the CSP on the control cabinet
The WorkVisual PC can either connect to the
robot controller via the KLI or it can be plugged
into the KSI.
Term Description
KSP KUKA Servo Pack
Drive controller
KSS KUKA System Software
Manipulator The robot arm and the associated electrical
installations
M{Number} Motor {Number}
NA North America
PELV Protective Extra Low Voltage
External 24 V power supply
QBS Operator safety acknowledgement signal
RDC Resolver Digital Converter (KR C4)
RDC cool Resolver Digital Converter (KR C4) with
extended temperature range
RTS Request To Send
Transmission request signal
SATA connections Data bus for exchanging data between the pro-
cessor and the hard drive
SG FC Servo Gun
SIB Safety Interface Board
SION Safety I/O Node
SOP SafeOperation
Option with software and hardware components
PLC A Programmable Logic Controller
is used in systems as a higher-level master mod-
ule in the bus system
SRM SafeRangeMonitoring
Safety option with software and hardware com-
ponents
SSB SafeSingleBrake
Safety option
US1 Load voltage (24 V) not switched
US2 Load voltage (24 V) switched. Deactivates actu-
ators, for example, when the drives are deacti-
vated
USB Universal Serial Bus
Bus system for connecting additional devices to
a computer
EA External axis (linear unit, Posiflex)
2 Purpose
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of electrical and electronic systems
Advanced knowledge of the robot controller
Advanced knowledge of the Windows operating system
3 Product description
Description The KUKA Power Pack (KPP) is the drive power supply and generates a rec-
tified intermediate circuit voltage from an AC power supply. This
intermediate circuit voltage is used to supply the internal drive controllers
and external drives. There are 4 different device variants, all having the
same size. There are LEDs on the KPP which indicate the operating state.
KPP without axis amplifier (KPP 600-20)
KPP with amplifier for one axis (KPP 600-20-1x40)
Peak output current 1x40 A
KPP with amplifier for two axes (KPP 600-20-2x40)
Peak output current 2x40 A
KPP with amplifier for three axes (KPP 600-20-3x20)
Peak output current 3x20 A
KPP with amplifier for one axis (KPP 600-20-1x64)
Peak output current 1x64 A
Description The KUKA Servo Pack (KSP) is the drive controller for the manipulator axes.
There are 3 different device variants, all having the same size. There are
LEDs on the KSP which indicate the operating state.
KSP for 3 axes (KSP 600-3x40)
Peak output current 3x 40 A
KSP for 3 axes (KSP 600-3x64)
Peak output current 3x 64 A
KSP for 3 axes (KSP 600-3x20)
Peak output current 3x 20 A
3.5 Control PC
Heat sink
Memory modules
Hard drive
LAN Dual NIC network card (not present on all motherboard variants)
PC fan
Optional modules, e.g. field bus cards
Functions The control PC (KPC) is responsible for the following functions of the robot
controller:
User interface
Program creation, correction, archiving, and maintenance
Sequence control
Path planning
Control of the drive circuit
Monitoring
Safety equipment
Communication with external periphery
(other controllers, host computers,
PCs, network)
Description The Cabinet Control Unit (CCU) is the central power distributor and communi-
cation interface for all components of the robot controller. The CCU consists
of the Cabinet Interface Board (CIB) and the Power Management Board
(PMB). All data are transferred via this internal communication interface to
the controller for further processing. If the mains voltage fails, the control
compo-nents continue to be powered by batteries until the position data are
saved and the controller has shut down. The charge and quality of the
batteries are checked by means of a load test.
Functions Communication interface for the components of the robot controller
Safe inputs and outputs
Control of main contactors 1 and 2
Mastering test
KUKA smartPAD plugged in
4 Fast Measurement inputs for customer applications
Monitoring of the fans in the robot controller
Fans
Control PC fan
Temperature sensing:
Thermostatic switch for transformer
Alarm contact for cooling unit
Alarm contact for main switch
Temperature sensor for ballast resistor
Temperature sensor for internal cabinet temperature
The following components are connected to the KPC via the KUKA Con-
troller Bus:
KPP/KSP
Resolver Digital Converter
The following operator panels and service devices are connected to the
control PC via the KUKA System Bus:
KUKA Operator Panel Interface
Diagnostic LEDs
Electronic Data Storage Interface
Power supply with battery backup
KPP
KSP
KUKA smartPAD
Multi-core control PC
Controller System Panel (CSP)
Resolver Digital Converter (RDC)
Standard SIB or Standard and Extended SIB (optional)
Power supply without battery backup
Motor brakes
External fan
Customer interface
Description The Safety Interface Board (SIB) is an integral part of the safety interface. 2
different SIBs are used in the robot controller, the Standard SIB and the Ex-
tended SIB, depending on the configuration of the safety interface. The Stan-
dard SIB and the Extended SIB incorporate sensing, control and switching
functions. The Extended SIB can only be operated together with the Standard
SIB. The output signals are provided as electrically isolated outputs.
The Standard SIB contains the following safe inputs and outputs:
5 safe inputs
3 safe outputs
The Extended SIB contains the following safe inputs and outputs:
8 safe inputs
8 safe outputs
Description The Resolver Digital Converter (RDC) is used to detect the motor position da-
ta. 8 resolvers can be connected to the RDC. In addition, the motor tempera-
tures are measured and evaluated. For non-volatile data storage, the EDS is
located in the RDC box.
2 different RDCs are used in the robot controller according to the specific
cus-tomer requirements:
RDC
Temperature range +5 ... 55 °C (278 ... 328 K)
RDC cool
Temperature range -30 ... +55 °C (243 ... 328 K)
If an RDC cool is used, an EDS cool must also be used.
USB2
KLI (optional)
KSI (optional)
Overview
Description The low-voltage power supply unit provides power to the components of the
robot controller.
A green LED indicates the operating state of the low-voltage power supply
unit.
3.12 Batteries
Description In the event of a power failure, or if the power is switched off, the batteries en-
able the robot controller to be shut down in a controlled manner. The
batteries are charged via the CCU and the charge is checked and indicated.
Overview
KPP
KSP, middle
KSP, left
RDC
CIB
EMD
Configuration
variants
PROFIBUS master
PROFIBUS slave
PROFIBUS master/slave
Expansion of digital I/Os 16/16
DeviceNet master
DeviceNet slave
DeviceNet master/slave
Configuration
variants
In the following cases a system modification must be carried out by the cus-
tomer using WorkVisual after connecting customer-specific devices to the
cor-responding interfaces:
Connection of PROFIBUS devices
Connection of EtherCAT devices
Overview The connection panel of the robot controller consists of connections for the fol-
lowing cables:
Power cable / infeed
Motor cables to the manipulator
Data cables to the manipulator
KUKA smartPAD cable
PE cables
Peripheral cables
The configuration of the connection panel varies according to the customer-
specific version and the options required.
Note The following safety interfaces can be configured in the robot controller:
Discrete safety interface X11
Ethernet safety interface X66
PROFIsafe KLI or
CIP Safety KLI
The discrete safety interface X11 and the Ethernet safety interface
X66 cannot be connected and used together.
Only one of the safety interfaces can be used at a time.
Connection panel
All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor
di-odes. RC elements and VCR resistors are not suitable.
Connection panel
Mx Motor x
Br Mx Brake, motor x
Connector
pin allocation
3.16.2 Connector pin allocation for motor connector X20 with 1 KPP and 1 KSP
Connector pin
allocation
Connector
pin allocation
Fig. 3-10: Connector pin allocation X20.1 and X20.4 for heavy-duty robot
3.16.5 Connector pin allocation X7.1 and X7.2 for external axes 1 and 2
3.16.6 Connector pin allocation X7.1, X7.2 and X7.3 for external axes 1, 2 and 3
Connector pin
allocation
Connector
pin allocation
3.16.9 Connector pin allocation X20.1 and X20.4 (heavy-duty palletizing robot) (5 axes)
Connector pin
allocation
Connector
pin allocation
3.16.13 Connector pin allocation X7.1 for palletizing robot, external axis 1
3.16.14 Connector pin allocation X7.1 and X7.2 for palletizing robot, for external axes 1 and 2
Connection panel
Mx Motor x
Br Mx Brake, motor x
Connector pin
allocation
Mx Motor x
Br Mx Brake, motor x
Motherboards The following motherboard variants can be installed in the control PC:
D2608-K
D3076-K
D3236-K
Overview
KUKA Roboter GmbH has assembled, tested and supplied the moth-
erboard with an optimum configuration. No liability will be accepted for
modifications to the configuration that have not been carried out
by KUKA Roboter GmbH.
Slot assignment
Overview
KUKA Roboter GmbH has assembled, tested and supplied the moth-
erboard with an optimum configuration. No liability will be accepted for
modifications to the configuration that have not been carried out
by KUKA Roboter GmbH.
Slot assignment
Overview
8 DVI-I (VGA support possible via DVI on VGA adapter). The user
inter-face of the controller can only be displayed on an external
monitor if no active operator control device (smartPAD, VRP) is
connected to the controller.
9 4 USB 2.0 ports
10 LAN Onboard – KUKA Option Network Interface
11 LAN Onboard – KUKA Line Interface
KUKA Roboter GmbH has assembled, tested and supplied the moth-
erboard with an optimum configuration. No liability will be accepted for
modifications to the configuration that have not been carried out
by KUKA Roboter GmbH.
Slot assignment
Description The optional KUKA smartPAD holder can be used to hang up the smartPAD
and its connecting cable on the door of the robot controller or on the
safety fence.
Overview
Description The set of rollers is designed for installation on the cabinet base or fork slots
of KR C4 robot controllers. The set of rollers enables the robot controller to
be easily rolled out of and into a bank of cabinets.
taining the control and power electronics, is cooled by a heat exchanger. In the
outer zone, the ballast resistor and the heat sinks of the KPP and KSP are
cooled directly by ambient air.
Configuration
Overview The space for integration of customer options can be used for external cus-
tomer equipment depending on the installed hardware options on the top-
hat rail.
4 Technical data
Basic data Cabinet type KR C4
Number of axes max. 9
Weight (without transformer) 150 kg
Protection rating IP 54
Sound level according to average: 67 dB (A)
DIN 45635-1
Installation with other cabinets Side-by-side, clearance 50 mm
(with/without cooling unit)
Load on cabinet roof with even dis- 1,500 N
tribution
Designation Values
Width 300 mm
Height 150 mm
Cable lengths For cable designations, standard lengths and optional lengths, please refer to
the operating instructions or assembly instructions of the manipulator and/or
the assembly and operating instructions for KR C4 external cabling for robot
controllers.
The cables of the power supply unit must not be routed together
with power-carrying cables.
SIB outputs
The power contacts must only be fed from a safely isolated PELV
power supply unit. (>>> 4.1 "External 24 V power supply" Page 65)
The module must be exchanged when the number of switching cycles is ex-
ceeded.
SIB inputs Switching level of the inputs The state for the inputs is not
defined for the voltage range from
5 V to 11 V (transition range). Either
the ON state or the OFF state is set.
OFF state for the voltage range
from -3 V to 5 V (OFF range).
ON state for the voltage range from
11 V to 30 V (ON range).
Load current with 24 V supply volt- > 10 mA
age
Load current with 18 V supply volt- > 6.5 mA
age
Max. load current < 15 mA
Cable length, terminal - sensor < 50 m, or < 100 m wire length (out-
going and incoming lines)
2
Cable cross-section, test output - > 0.5 mm
input connection
Capacitive load for the test outputs < 200 nF
per channel
Resistive load for the test outputs <33Ω
per channel
1 Front view
2 Side view
3 Top view
The minimum clearances that must be maintained for the robot controller
are indicated in the diagram (>>> Fig. 4-2 ).
The diagram (>>> Fig. 4-3 ) shows the swing range for the door.
The diagram (>>> Fig. 4-4 ) shows the dimensions and drilling locations for
mounting on the robot controller or safety fence.
The dimensions of the boreholes for floor mounting are indicated in the dia-
gram (>>> Fig. 4-5 ).
The diagram (>>> Fig. 4-6 ) shows the dimensions of the boreholes on the
KR C4 for fastening the technology cabinet.
Overview The following plates and labels are attached to the robot controller.
The plates may vary slightly from the examples illustrated above de-
pending on the specific cabinet type or as a result of updates.
Designations
Plate no. Designation
1 Robot controller rating plate
2 Hot surface warning sign
3 Hand injury warning sign
4 Information sign: KR C4 main switch
5 Warning: ≤ 780 VDC / wait 180 s
6 Warning: read manual
7 Control PC rating plate
5 Safety
5.1 General
5.1.1 Liability
Safety infor- Safety information cannot be held against KUKA Roboter GmbH. Even if all
mation safety instructions are followed, this is not a guarantee that the industrial
robot will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the autho-
rization of KUKA Roboter GmbH. Additional components (tools, software,
etc.), not supplied by KUKA Roboter GmbH, may be integrated into the
indus-trial robot. The user is liable for any damage these components may
cause to the industrial robot or to other material property.
In addition to the Safety chapter, this document contains further safety
instruc-tions. These must also be observed.
The industrial robot is intended exclusively for the use designated in the
“Pur-pose” chapter of the operating instructions or assembly instructions.
Any use or application deviating from the intended use is deemed to be
misuse and is not allowed. The manufacturer is not liable for any damage
resulting from such misuse. The risk lies entirely with the user.
Operation of the industrial robot in accordance with its intended use also re-
quires compliance with the operating and assembly instructions for the individ-
ual components, with particular reference to the maintenance specifications.
Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. This includes e.g.:
Declaration of The system integrator must issue a declaration of conformity for the
conformity complete system in accordance with the Machinery Directive. The
declaration of confor-mity forms the basis for the CE mark for the system.
The industrial robot must always be operated in accordance with the
applicable national laws, regula-tions and standards.
The robot controller is CE certified under the EMC Directive and the Low
Volt-age Directive.
STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204-
1:2006.
Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may move.
The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance
The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived from
the individual axis ranges.
Term Description
User The user of the industrial robot can be the management, employer or
delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distances
of the manipulator and external axes (optional).
Service life The service life of a safety-relevant component begins at the time of
delivery of the component to the customer.
The service life is not affected by whether the component is used or not,
as safety-relevant components are also subject to aging during storage.
KUKA smartPAD see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safe operational stop The safe operational stop is a standstill monitoring function. It does not
stop the robot motion, but monitors whether the robot axes are station-
ary. If these are moved during the safe operational stop, a safety stop
STOP 0 is triggered.
The safe operational stop can also be triggered externally.
When a safe operational stop is triggered, the robot controller sets an
output to the field bus. The output is set even if not all the axes were sta-
tionary at the time of triggering, thereby causing a safety stop STOP 0 to
be triggered.
Safety STOP 0 A stop that is triggered and executed by the safety controller. The safety
controller immediately switches off the drives and the power supply to
the brakes.
Note: This stop is called safety STOP 0 in this document.
Safety STOP 1 A stop that is triggered and monitored by the safety controller. The brak-
ing process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. As soon as the manip-
ulator is at a standstill, the safety controller switches off the drives and
the power supply to the brakes.
When a safety STOP 1 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 1 can also be triggered externally.
Note: This stop is called safety STOP 1 in this document.
Safety STOP 2 A stop that is triggered and monitored by the safety controller. The brak-
ing process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. The drives remain acti-
vated and the brakes released. As soon as the manipulator is at a stand-
still, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 2 can also be triggered externally.
Note: This stop is called safety STOP 2 in this document.
Safety options Generic term for options which make it possible to configure additional
safe monitoring functions in addition to the standard safety functions.
Example: SafeOperation
Term Description
Stop category 0 The drives are deactivated immediately and the brakes are applied. The
manipulator and any external axes (optional) perform path-oriented
braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-main-
taining braking.
Operating mode T1: The drives are deactivated as soon as the robot
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a path-
maintaining braking ramp.
Note: This stop category is called STOP 2 in this document.
System integrator The system integrator is responsible for safely integrating the industrial
(plant integrator) robot into a complete system and commissioning it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Motion axis which is not part of the manipulator but which is controlled
using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.
5.2 Personnel
The following persons or groups of persons are defined for the industrial robot:
User
Personnel
All persons working with the industrial robot must have read and
un-derstood the industrial robot documentation, including the safety
chapter.
User The user must observe the labor laws and regulations. This includes e.g.:
The user must comply with his monitoring obligations.
work involved and what exactly it entails as well as any hazards which may ex-
ist. Instruction must be carried out regularly. Instruction is also required after
particular incidents or technical modifications.
Personnel includes:
System integrator
Operators, subdivided into:
Start-up, maintenance and service personnel
Operator
Cleaning personnel
System integrator The industrial robot is safely integrated into a complete system by the
system integrator.
The system integrator is responsible for the following tasks:
Installing the industrial robot
Connecting the industrial robot
Performing risk assessment
Implementing the required safety functions and safeguards
Issuing the declaration of conformity
Attaching the CE mark
Creating the operating instructions for the complete system
The system integrator’s risk assessment may indicate that the stopping dis-
tances must be determined for an application. In order to determine the stop
- ping distances, the system integrator must identify the safety-relevant
points on the programmed path.
When determining the stopping distances, the robot must be moved with the tool
and loads which are also used in the application. The robot must be at op-erating
temperature. This is the case after approx. 1 h in normal operation.
During execution of the application, the robot must be stopped at the point
from which the stopping distance is to be calculated. This process must be
re-peated several times with a safety stop 0 and a safety stop 1. The least
favor-able stopping distance is decisive.
A safety stop 0 can be triggered by a safe operational stop via the safety
inter-face, for example. If a safety option is installed, it can be triggered, for
in-stance, by a space violation (e.g. the robot exceeds the limit of an
activated workspace in Automatic mode).
A safety stop 1 can be triggered by pressing the EMERGENCY STOP
device on the smartPAD, for example.
KUKA smartPAD
Cabinet Control Unit (CCU)
Resolver Digital Converter (RDC)
KUKA Power Pack (KPP)
KUKA Servo Pack (KSP)
Safety Interface Board (SIB) (if used)
There are also interfaces to components outside the industrial robot and
to other robot controllers.
The safety controller is a unit inside the control PC. It links safety-relevant
sig-nals and safety-relevant monitoring functions.
Safety controller tasks:
Switching off the drives; applying the brakes
Monitoring the braking ramp
Standstill monitoring (after the stop)
Velocity monitoring in T1
Evaluation of safety-relevant signals
Setting of safety-oriented outputs
The “operator safety” signal is used for interlocking physical safeguards, e.g.
safety gates. Automatic operation is not possible without this signal. In the
event of a loss of signal during automatic operation (e.g. safety gate is
opened), the manipulator stops with a safety stop 1.
Operator safety is not active in modes T1 (Manual Reduced Velocity) and
T2 (Manual High Velocity).
Every operator station that can initiate a robot motion or other potentially
haz-ardous situation must be equipped with an EMERGENCY STOP device.
The system integrator is responsible for ensuring this.
There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the smartPAD is disconnected.
External EMERGENCY STOP devices are connected via the customer inter-
face. External EMERGENCY STOP devices are not included in the scope of
supply of the industrial robot.
The enabling devices of the industrial robot are the enabling switches on the
smartPAD.
There are 3 enabling switches installed on the smartPAD. The enabling
switches have 3 positions:
Not pressed
Center position
Panic position
In the test modes, the manipulator can only be moved if one of the enabling
switches is held in the central position.
Releasing the enabling switch triggers a safety stop 2.
Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
It is possible to hold 2 enabling switches in the center position simultane-
ously for up to 15 seconds. This makes it possible to adjust grip from one
enabling switch to another one. If 2 enabling switches are held
simultane-ously in the center position for longer than 15 seconds, this
triggers a safe-ty stop 1.
If an enabling switch malfunctions (jams), the industrial robot can be
stopped using the following methods:
Press the enabling switch down fully
Actuate the EMERGENCY STOP system
Release the Start key
External enabling devices are required if it is necessary for more than one
per-son to be in the danger zone of the industrial robot.
External enabling devices are not included in the scope of supply of the
indus-trial robot.
The safe operational stop can be triggered via an input on the customer inter-
face. The state is maintained as long as the external signal is FALSE. If the
Safety stop 1 and safety stop 2 can be triggered via an input on the
customer interface. The state is maintained as long as the external signal is
FALSE. If the external signal is TRUE, the manipulator can be moved again.
No ac-knowledgement is required.
The axis ranges of all manipulator and positioner axes are limited by means
of adjustable software limit switches. These software limit switches only
serve as machine protection and must be adjusted in such a way that the
manipulator/ positioner cannot hit the mechanical end stops.
The software limit switches are set during commissioning of an industrial ro-
bot.
Depending on the robot variant, the axis ranges of the main and wrist axes
of the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.
This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Roboter GmbH.
This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Roboter GmbH.
The system user is responsible for ensuring that the training of per-
sonnel with regard to the response to emergencies or exceptional sit-
uations also includes how the manipulator can be moved without
drive energy.
Description The following options are available for moving the manipulator without drive
The release device can be used for the main axis drive motors and, de-
pending on the robot variant, also for the wrist axis drive motors.
Brake release device (option)
The brake release device is designed for robot variants whose motors are
not freely accessible.
All plates, labels, symbols and marks constitute safety-relevant parts of the
in-dustrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
Identification plates
Warning signs
Safety symbols
Designation labels
Cable markings
Rating plates
The access of persons to the danger zone of the industrial robot must be
pre-vented by means of safeguards. It is the responsibility of the system
integrator to ensure this.
Physical safeguards must meet the following requirements:
They meet the requirements of EN 953.
They prevent access of persons to the danger zone and cannot be
easily circumvented.
They are sufficiently fastened and can withstand all forces that are likely
to occur in the course of operation, whether from inside or outside the
en-closure.
They do not, themselves, represent a hazard or potential hazard.
The prescribed minimum clearance from the danger zone is maintained.
Safety gates (maintenance gates) must meet the following requirements:
They are reduced to an absolute minimum.
The interlocks (e.g. safety gate switches) are linked to the operator
safety input of the robot controller via safety gate switching devices or
safety PLC.
Switching devices, switches and the type of switching conform to the re-
quirements of Performance Level d and category 3 according to EN ISO
13849-1.
Depending on the risk situation: the safety gate is additionally
safeguarded by means of a locking mechanism that only allows the gate
to be opened if the manipulator is safely at a standstill.
The button for acknowledging the safety gate is located outside the
space limited by the safeguards.
Other safety Other safety equipment must be integrated into the system in accordance
equipment with the corresponding standards and regulations.
The following table indicates the operating modes in which the safety
functions are active.
Safety functions T1 T2 AUT AUT EXT
Operator safety - - active active
EMERGENCY STOP device active active active active
Enabling device active active - -
Reduced velocity during pro- active - - -
gram verification
Jog mode active active - -
Software limit switches active active active active
The industrial robot may only be used in perfect technical condition in accor-
dance with its intended use and only by safety-conscious persons. Operator
errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial robot
even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake
defect) can cause the manipulator or external axes to sag. If work is to be
carried out on a switched-off industrial robot, the manipulator and external
axes must first be moved into a position in which they are unable to move on
their own, whether the payload is mounted or not. If this is not possible, the
manipulator and ex-ternal axes must be secured by appropriate means.
the required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety functions
must also be tested.
New or modified programs must always be tested first in Manual Reduced Ve-
locity mode (T1).
After modifications to the industrial robot, existing programs must always be
tested first in Manual Reduced Velocity mode (T1). This applies to all compo-
nents of the industrial robot and includes modifications to the software and
configuration settings.
Faults The following tasks must be carried out in the case of faults in the industrial
robot:
Switch off the robot controller and secure it (e.g. with a padlock) to prevent
Manipulator The prescribed transport position of the manipulator must be observed. Trans-
Before starting up systems and devices for the first time, a check must be car-
ried out to ensure that the systems and devices are complete and operational,
that they can be operated safely and that any damage is detected.
The valid national or regional work safety regulations must be observed for this
check. The correct functioning of all safety functions must also be tested.
The passwords for the user groups must be changed in the KUKA
System Software before start-up. The passwords must only be
com-municated to authorized personnel.
If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Roboter GmbH, are integrated into the industrial
robot, the user is responsible for ensuring that these components do
not adversely affect or disable safety functions.
If the internal cabinet temperature of the robot controller differs greatly from
the ambient temperature, condensa-tion can form, which may cause
damage to the electrical components. Do not
put the robot controller into operation until the internal temperature of the
cabinet has adjusted to the ambient temperature.
Function test The following tests must be carried out before start-up and recommissioning:
General test:
It must be ensured that:
The industrial robot is correctly installed and fastened in accordance
with the specifications in the documentation.
There are no foreign bodies or loose parts on the industrial robot.
All required safety equipment is correctly installed and operational.
The power supply ratings of the industrial robot correspond to the local
supply voltage and mains type.
The ground conductor and the equipotential bonding cable are
sufficiently rated and correctly connected.
The connecting cables are correctly connected and the connectors are
locked.
Test of the safety functions:
A function test must be carried out for the following safety functions to
ensure that they are functioning correctly:
Local EMERGENCY STOP device
External EMERGENCY STOP device (input and output)
Enabling device (in the test modes)
Operator safety
General If practical tests are required for the machine data, this test must always be
practical test carried out.
The following methods are available for performing the practical test:
TCP calibration with the XYZ 4-point method
The practical test is passed if the TCP has been successfully calibrated.
Or:
1. Align the TCP with a freely selected point.
The point serves as a reference point. It must be located so that
reorien-tation is possible.
2. Move the TCP manually at least 45° once in each of the A, B and C
direc-tions.
The movements do not have to be accumulative, i.e. after motion in one
direction it is possible to return to the original position before moving in
the next direction.
The practical test is passed if the TCP does not deviate from the
reference point by more than 2 cm in total.
Practical test for If practical tests are required for the machine data, this test must be carried
axes that are not out when axes are present that are not mathematically coupled.
mathematically 1. Mark the starting position of the axis that is not mathematically coupled.
coupled 2. Move the axis manually by a freely selected path length. Determine the
path length from the display Actual position on the smartHMI.
Move linear axes a specific distance.
Move rotational axes through a specific angle.
3. Measure the length of the path covered and compare it with the value
dis-played on the smartHMI.
The practical test is passed if the values differ by no more than 10%.
4. Repeat the test for each axis that is not mathematically coupled.
Practical test for If practical tests are required for the machine data, this test must be carried
couplable axes out when axes are present that can be physically coupled and uncoupled,
e.g. a servo gun.
1. Physically uncouple the couplable axis.
2. Move all the remaining axes individually.
The practical test is passed if it has been possible to move all the
remain-ing axes.
Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 without the external
safeguards being put into operation.
When Start-up mode is possible depends on the safety interface that is used.
Discrete safety interface
System Software 8.2 or earlier:
Start-up mode is always possible if all input signals at the discrete safety
interface have the state “logic zero”. If this is not the case, the robot con-
troller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the in-
puts there must also have the state “logic zero”.
System Software 8.3 or higher:
Start-up mode is always possible. This also means that it is independent
of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection to a
higher-level safety system exists or is established.
Effect When the Start-up mode is activated, all outputs are automatically set to the
state “logic zero”.
If the robot controller has a peripheral contactor (US2), and if the safety con-
figuration specifies for this to switch in accordance with the motion enable,
then the same also applies in Start-up mode. This means that if motion
enable is present, the US2 voltage is switched on – even in Start-up mode.
Use of Start -up mode disables all external safeguards. The service
personnel are responsible for ensuring that there is no-one in or near the
danger zone of the manipulator as long as the
safeguards are disabled.
Failure to observe this precaution may result in death, injuries or damage
to property.
Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. KUKA Roboter GmbH is not liable for any damage
resulting from such misuse. The risk lies entirely with the user.
Manual mode is the mode for setup work. Setup work is all the tasks that
have to be carried out on the industrial robot to enable automatic operation.
Setup work includes:
Jog mode
Teaching
Programming
Program verification
The following must be taken into consideration in manual mode:
New or modified programs must always be tested first in Manual
Reduced Velocity mode (T1).
The manipulator, tooling or external axes (optional) must never touch
or project beyond the safety fence.
Workpieces, tooling and other objects must not become jammed as a re-
sult of the industrial robot motion, nor must they lead to short-circuits or
be liable to fall off.
All setup work must be carried out, where possible, from outside the
safe-guarded area.
If the setup work has to be carried out inside the safeguarded area, the
follow-ing must be taken into consideration:
In Manual Reduced Velocity mode (T1):
If it can be avoided, there must be no other persons inside the
safeguard-ed area.
If it is necessary for there to be several persons inside the safeguarded
ar-ea, the following must be observed:
Each person must have an enabling device.
All persons must have an unimpeded view of the industrial robot.
5.8.5 Simulation
After maintenance and repair work, checks must be carried out to ensure
the required safety level. The valid national or regional work safety
regulations must be observed for this check. The correct functioning of all
safety functions must also be tested.
The purpose of maintenance and repair work is to ensure that the system is
kept operational or, in the event of a fault, to return the system to an
operation - al state. Repair work includes troubleshooting in addition to the
actual repair itself.
The following safety measures must be carried out when working on the
indus-trial robot:
Carry out work outside the danger zone. If work inside the danger zone
is necessary, the user must define additional safety measures to ensure
the safe protection of personnel.
Switch off the industrial robot and secure it (e.g. with a padlock) to
prevent it from being switched on again. If it is necessary to carry out
work with the robot controller switched on, the user must define
additional safety mea-sures to ensure the safe protection of personnel.
If it is necessary to carry out work with the robot controller switched on,
this may only be done in operating mode T1.
Label the system with a sign indicating that work is in progress. This sign
must remain in place, even during temporary interruptions to the work.
Counterbal- Some robot variants are equipped with a hydropneumatic, spring or gas
ancing system cylin-der counterbalancing system.
The hydropneumatic and gas cylinder counterbalancing systems are
pressure equipment and, as such, are subject to obligatory equipment
monitoring and the provisions of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and
stan-dards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order,
Sections 14 and 15. Inspection by the user before commissioning at the
instal-lation site.
The following safety measures must be carried out when working on the
coun-terbalancing system:
The manipulator assemblies supported by the counterbalancing
systems must be secured.
Work on the counterbalancing systems must only be carried out by quali-
fied personnel.
Hazardous The following safety measures must be carried out when handling
substances hazardous substances:
Avoid prolonged and repeated intensive contact with the skin.
Avoid breathing in oil spray or vapors.
Clean skin and apply skin cream.
Overview If certain components in the industrial robot are operated, safety measures
must be taken to ensure complete implementation of the principle of “single
point of control” (SPOC).
The relevant components are:
Submit interpreter
PLC
OPC Server
Remote control tools
Tools for configuration of bus systems with online functionality
KUKA.RobotSensorInterface
Since only the system integrator knows the safe states of actuators in the pe-
riphery of the robot controller, it is his task to set these actuators to a safe
state, e.g. in the event of an EMERGENCY STOP.
T1, T2 In modes T1 and T2, the components referred to above may only access
the industrial robot if the following signals have the following states:
Signal State required for SPOC
$USER_SAF TRUE
$SPOC_MOTION_ENABLE TRUE
Submit inter- If motions, (e.g. drives or grippers) are controlled with the submit interpreter
preter, PLC or the PLC via the I/O system, and if they are not safeguarded by other
means, then this control will take effect even in T1 and T2 modes or while an
EMER-GENCY STOP is active.
If variables that affect the robot motion (e.g. override) are modified with the
submit interpreter or the PLC, this takes effect even in T1 and T2 modes or
while an EMERGENCY STOP is active.
Safety measures:
In T1 and T2, the system variable $OV_PRO must not be written to by
the submit interpreter or the PLC.
Do not modify safety-relevant signals and variables (e.g. operating
mode, EMERGENCY STOP, safety gate contact) via the submit
interpreter or PLC.
If modifications are nonetheless required, all safety-relevant signals and
variables must be linked in such a way that they cannot be set to a dan-
gerous state by the submit interpreter or PLC. This is the responsibility
of the system integrator.
OPC server, These components can be used with write access to modify programs,
remote control outputs or other parameters of the robot controller, without this being noticed
by any persons located inside the system.
tools
Safety measure:
If these components are used, outputs that could cause a hazard must be
de-termined in a risk assessment. These outputs must be designed in such a
way that they cannot be set without being enabled. This can be done using
an ex-ternal enabling device, for example.
Tools for configu- If these components have an online functionality, they can be used with write
ration of bus access to modify programs, outputs or other parameters of the robot control-ler,
systems without this being noticed by any persons located inside the system.
WorkVisual from KUKA
Tools from other manufacturers
Safety measure:
In the test modes, programs, outputs or other parameters of the robot
control-ler must not be modified using these components.
6 Planning
Overview Step Description Information
1 Electromagnetic compati- (>>> 6.1 "Electromagnetic com-
bility (EMC) patibility (EMC)" Page 97)
2 Installation conditions for (>>> 6.2 "Installation condi-
robot controller tions" Page 97)
3 Connection conditions (>>> 6.3 "Connection condi-
tions" Page 100)
4 Mounting the KUKA smart- (>>> 4.6 "Dimensions of the
PAD holder (optional) smartPAD holder (optional)"
Page 68)
5 Power supply connection (>>> 6.5 "Power supply connec-
tion via X1 Harting connector"
Page 102)
6 Safety interface X11 (>>> 6.6.1 "Safety interface
X11" Page 104)
7 Ethernet safety interface (>>> 6.7 "Safety functions via
X66 Ethernet safety interface
(optional)" Page 112)
8 EtherCAT connection on (>>> 6.8 "EtherCAT connection
the CIB on the CIB" Page 120)
9 PE equipotential bonding (>>> 6.9 "PE equipotential
bonding" Page 120)
10 Modification of the system (>>> 6.10 "Modifying the sys-
structure, exchange of tem configuration, exchanging
devices devices" Page 122)
11 Acknowledgement of oper- (>>> 6.11 "Operator safety
ator safety acknowledgement" Page 122)
12 Performance Level (>>> 6.12 "Performance level"
Page 122)
Description If connecting cables (e.g. field buses, etc.) are routed to the control PC from
outside, only shielded cables with an adequate degree of shielding may be
used. The cable shield must be connected with maximum surface area to the
PE rail in the cabinet using shield terminals (screw-type, no clamps).
1 Front view
2 Side view
3 Top view
The minimum clearances that must be maintained for the robot controller
are indicated in the diagram (>>> Fig. 6-2 ).
Robot controller One robot controller can be stacked on top of another one. The upper robot
stacked controller, with standard cabinet base only, must be firmly screwed to the low-er
one. To do so, the 4 threads of the eyebolts must be used. The lower robot
controller must not be mounted on rollers and must be fastened to the floor.
A stacked robot controller is illustrated in the diagram (>>> Fig. 6-4 ).
Power supply
If the robot controller is connected to a power system
connection without a grounded neutral or is operated with incorrect
machine data, this may cause malfunctions in the robot controller and
mate-rial damage to the power supply units. Electrical voltage can cause
injuries. The robot controller may only be operated with grounded-neutral
power sup-ply systems.
If no grounded neutral is available, or if the mains voltage differs from those
specified here, a transformer must be used.
Rated supply voltage according to AC 3x380 V, AC 3x400 V,
the machine data, optionally: AC 3x440 V or AC 3x480 V
Permissible tolerance of rated sup- Rated supply voltage ±10%
ply voltage
Mains frequency 49 ... 61 Hz
System impedance up to the con- ≤ 300 mΩ
nection point of the robot controller
Full-load current See identification plate
Mains-side fusing without trans- min. 3x25 A, slow-blowing
former
Mains-side fusing with transformer min. 3x32 A, slow-blowing, with
13 kVA
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit.
100 / 221 Issued: 26.01.2015 Version: BA KR C4 GI V11
6 Planning
The cables of the power supply unit must not be routed together
with power-carrying cables.
Overview The smartPAD holder can be installed on the door of the robot controller or on
the safety fence.
The following diagram (>>> Fig. 6-5 ) shows the options for fastening the
smartPAD holder.
2 Spring lock washer A6.1 and 4 Iron flat for fence mounting
plain washer
can connect the robot controller to the power supply via connector X1.
Description EMERGENCY STOP devices must be connected via safety interface X11 or
linked together by means of higher-level controllers (e.g. PLC). (>>> "SIB
outputs" Page 65)
Wiring Take the following points into consideration when wiring safety interface X11:
System concept
Safety concept
Connector pin
allocation
Safe operational 8 Safe operational stop input for all Activation of standstill monitoring
stop, channel A axes Stop 0 is initiated if the activated
Safe operational 26 monitoring is violated.
stop, channel B
Safety stop, Stop 10 Safety stop (Stop 2) input for all Triggering of Stop 2 and activa-
2 channel A axes tion of standstill monitoring at
Safety stop, Stop 28 standstill of all axes.
2 channel B Stop 0 is initiated if the activated
monitoring is violated.
Local E-STOP 37 Output, floating contacts from The contacts are closed if the
channel A 38 internal E-STOP, (>>> "SIB out- following conditions are met:
puts" Page 65) E-STOP on smartPAD not
Local E-STOP 55
channel B 56 actuated
Controller switched on and
operational
The contacts open if any condi-
tion is not met.
External E-STOP 2 Dual-channel E-STOP input, Triggering of the E-STOP func-
channel A (>>> "SIB inputs" Page 66) tion in the robot controller.
External E-STOP 20
channel B
Acknowledge 6 For connection of a dual-channel The response of the “Operator
operator safety, input for acknowledging operator safety acknowledgement” input
channel A safety with floating contacts, can be configured in the KUKA
Acknowledge 24 (>>> "SIB inputs" Page 66) system software.
operator safety, After closing the safety gate
channel B (operator safety), manipulator
motion can be enabled in the
automatic modes using an
acknowledge button outside the
safety fence. This function is
deactivated on delivery.
Operator safety, 4 For 2-channel connection of a As long as the signal is active,
channel A safety gate locking mechanism, the drives can be switched on.
Operator safety, 22 (>>> "SIB inputs" Page 66) Only effective in the AUTO-
channel B MATIC modes.
Signal “Peri The signal “Peri enabled” is set to 1 (active) if the following conditions are met:
enabled” (PE) Drives are switched on.
Safety controller motion enable signal present.
The message “Operator safety open” must not be active.
This message is only active in the modes T1 and T2.
“Peri enabled” in conjunction with the signal “Safe operational stop”
In the case of activation of the signal “Safe operational stop” during the
motion:
Error -> braking with Stop 0. “Peri enabled” eliminated.
Activation of the signal “Safe operational stop” with the manipulator sta-
tionary:
Release the brakes, switch drives to servo-control and monitor for
restart. “Peri enabled” remains active.
Signal “Motion enable” remains active.
US2 voltage (if present) remains active.
Signal “Peri enabled” remains active.
Connector
pin allocation
Contact diagram,
connector X11
In the cabling for the output signals and test signals in the system,
suitable measures must be taken to prevent a cross- connection
be-tween the output signals of a channel (e.g. separate cabling).
Description The EMERGENCY STOP devices are connected to X11 in the robot control-
ler.
EMERGENCY
The EMERGENCY STOP devices on the robot controller
STOP must be integrated into the EMERGENCY STOP circuit
of the system by the system integrator.
Failure to do this may result in death, severe injuries or considerable
damage to property.
safeguard. The closing of the safety gate must be confirmed by pressing the
acknowledge button before the industrial robot can be started again in Auto-
matic mode.
The inputs of the SIB are of dual-channel design with external testing. The
dual-channel operation of the inputs is monitored cyclically.
The following diagram illustrates the connection of a safe input to a floating
contact provided by the customer.
2 SIB/CIB
3 Robot controller
4 Interface X11 (XD211) or X13 (XD213)
5 Test output channel B
6 Test output channel A
7 Input X, channel A
8 Input X, channel B
9 System side
10 Floating contact
Test outputs A and B are fed with the supply voltage of the SIB. Test outputs
A and B are sustained short-circuit proof. The test outputs must only be used
to supply the SIB inputs, and for no other purpose.
The wiring example described can be used to achieve compliance with Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.
Dynamic testing The switch-off capability of the inputs is tested cyclically. For this, the test
Switch-off pulse
diagram
Safe output On the SIB, the outputs are provided as dual-channel floating relay outputs.
The following diagram illustrates the connection of a safe output to a safe
input provided by the customer with external test facility. The input used by
the cus-tomer must be monitored externally for cross-connection.
1 SIB
2 Robot controller
3 Interface X11 (XD211) or X13 (XD213)
4 Output wiring
5 System side
6 Safe input (Fail Safe PLC, safety switching device)
7 Test output channel B
8 Test output channel A
9 Input X, channel A
10 Input X, channel B
The wiring example described can be used to achieve compliance with Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.
Description The exchange of safety-relevant signals between the controller and the sys-
tem is carried out via the Ethernet safety interface (e.g. PROFIsafe or CIP
Safety). The assignment of the input and output states within the Ethernet
safety interface protocol are listed below. In addition, non-safety-oriented in-
formation from the safety controller is sent to the non-safe section of the high-
er-level controller for the purpose of diagnosis and control.
Reserved bits Reserved safe inputs can be pre-assigned by a PLC with the values 0 or 1. In
both cases, the manipulator will move. If a safety function is assigned to a re-
served input (e.g. in the case of a software update) and if this input is preset
with the value 0, then the manipulator would either not move or would unex-
pectedly come to a standstill.
2 BS Operator safety
0 = operator safety is not active, e.g. safety gate open
1 = operator safety is active
6 RES -
7 RES -
Input byte 1
Bit Signal Description
0 US2 Supply voltage US2 (signal for switching the second
supply voltage, US2, without battery backup)
If this output is not used, it should be set to 0.
0 = switch off US2
1 = switch on US2
Note: Whether and how input US2 is used must be
specified under Hardware options in the safety con-
figuration. Information is contained in the Operating
and Programming Instructions for System Integra-
tors.
1 SBH Safe operational stop (all axes)
Precondition: All axes are stationary
Cancelation of this function does not require acknowl-
edgement.
This function is not permissible for the EMERGENCY
STOP function.
0 = safe operational stop is active.
1 = safe operational stop is not active.
2 RES Reserved 11
The value 1 must be assigned to the input.
3 RES Reserved 12
The value 1 must be assigned to the input.
5 RES Reserved 14
The value 1 must be assigned to the input.
6 RES Reserved 15
The value 1 must be assigned to the input.
1 BS Operator safety
0 = operator safety is not assured
1 = operator safety is assured (input BS = 1 and, if
configured, input QBS acknowledged)
2 SHS1 Safety stop 1 (all axes)
0 = Safety stop 1 is not active
1 = Safety stop 1 is active (safe state reached)
4 RES Reserved 13
5 RES Reserved 14
6 PSA Safety interface active
Precondition: An Ethernet interface must be installed
on the controller, e.g. PROFINET or Ethernet/IP
0 = safety interface is not active
1 = safety interface is active
Description An external enabling switch can be connected to the higher-level safety con-
troller. The signals (ZSE make contact and External panic break contact)
must be correctly linked to the Ethernet safety interface signals in the safety
control-ler. The resulting Ethernet safety interface signals must then be
routed to the PROFIsafe of the KR C4. The response to the external
enabling switch is then identical to that for a discretely connected X11.
Signals
Description The components of the industrial robot move within the limits that have been
configured and activated. The actual positions are continuously calculated and
monitored against the safety parameters that have been set. The safety con-
troller monitors the industrial robot by means of the safety parameters that
have been set. If a component of the industrial robot violates a monitoring limit
or a safety parameter, the manipulator and external axes (optional) are
stopped. The Ethernet safety interface can be used, for example, to signal a
violation of safety monitoring functions.
In the case of the KR C4 compact robot controller, safety options such as Sa-
feOperation are only available via the Ethernet safety interface from KSS/
VSS 8.3 onwards.
Reserved bits Reserved safe inputs can be pre-assigned by a PLC with the values 0 or 1. In
both cases, the manipulator will move. If a safety function is assigned to a re-
served input (e.g. in the case of a software update) and if this input is preset
with the value 0, then the manipulator would either not move or would unex-
pectedly come to a standstill.
Input byte 6
Bit Signal Description
0…7 WZ1…8 Tool selection 1 … 8
Assignment: Bit 0 = tool 1 … bit 7 = tool 8
0 = tool is not active.
1 = tool is active.
Exactly one tool must be selected at all times.
1 RR Manipulator referenced
Mastering test display
0 = mastering test required.
1 = mastering test performed successfully.
2 JF Mastering error
Space monitoring is deactivated because at
least one axis is not mastered.
0 = mastering error. Space monitoring has been
deactivated.
1 = no error.
Description Connector X66 on the connection panel is intended for connecting an external
computer for the purpose of installation, programming, debugging and
diagno-sis.
Connector
pin allocation
Description Connector X44 on the CIB is the interface for connection of EtherCAT slaves
inside the robot controller (on the mounting plate for customer components).
The EtherCAT line remains in the robot controller. The EtherCAT line can be
routed out of the robot controller via the optional connector X65. Information
about connector X65 can be found in the assembly and operating
instructions of the optional KR C4 interfaces.
1 CIB
2 EtherCAT connection X44
Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
Installation of KSS/VSS 8.2 or higher
This is the case if KSS/VSS 8.2 or higher is installed without KSS/VSS
8.2 or higher already being present (because it has been uninstalled or
delet-ed or has never been installed).
The hard drive has been exchanged.
A device has been replaced by a device of a different type.
More than one device has been replaced by a device of a different type.
One or more devices have been removed.
One or more devices have been added.
Exchanging If a device is exchanged, at least one KCB, KSB or KEB device is replaced by
devices a device of the same type. Any number of KCB, KSB and KEB devices can be
exchanged until all devices in the KCB, KSB and KEB have been replaced si-
multaneously by devices of the same type. Simultaneous exchange of two
identical components of the KCB is not possible. Only one of the identical com-
ponents may be exchanged at any one time.
The safety functions of the robot controller conform to category 3 and Perfor-
mance Level d according to EN ISO 13849-1.
For controller variants that are not listed here, please contact KUKA
Roboter GmbH.
7 Transportation
Procedure 1. Screw the eyebolts into the robot controller. The eyebolts must be fully
screwed in and flush with the mounting surface.
2. Attach the lifting tackle with or without a lifting frame to all 4 eyebolts on
the robot controller.
Transportation The robot controller can be picked up using a fork lift truck. The robot
with standard controller must not be damaged when inserting the forks beneath the robot
cabinet base controller. After insertion, the forks of the fork lift truck must be opened until
they are in contact with the cabinet bases.
Transportation The robot controller can be picked up by fork lift truck using two fork slots
using fork slots (op-tion).
1 Fork slots
Transportation The robot controller with transformer (option) can be picked up by fork lift
with transformer truck using two fork slots.
1 Fork slots
2 Transformer
Transportation The robot controller with the set of rollers (option) can be picked up by fork
with the set of lift truck. For this, the forks of the fork lift truck must be inserted between the
rollers anti-toppling bracket and the cross-strut of the roller set.
1 Anti-toppling bracket
2 Cross-strut of the roller set
Transportation
by pallet truck
1 Anti-toppling bracket
Description The robot controller rollers may only be used to roll the cabinet into and out of
a row of cabinets – not to transport the cabinet over longer distances. The floor
must be level and free from obstacles, as there is a permanent risk of toppling.
This overview refers to the start-up of the industrial robot. The start-up
of the overall system is not within the scope of this documentation.
Manipulator
Accessories Precondition: the manipulator is ready to move, i.e. the software start-up has
been carried out up to and including the item “Master the manipulator
without load”.
Description Information
Optional: install and adjust external energy supply system, Detailed information can be found
taking the programming into consideration. in the energy supply system docu-
mentation.
Positionally accurate manipulator option: check data.
nets, etc. must be observed. (>>> 6.2 "Installation conditions" Page 97)
2. Check the robot controller for any damage caused during transportation.
Procedure 1. Route and connect the motor cables to the manipulator junction box sep-
arately from the data cables.
2. Route and connect the motor cables of the external axes.
3. Route the data cables to the manipulator junction box separately from the
motor cable. Plug in connector X21.
4. Connect the peripheral cables.
Connector pin
allocation
Procedure Fasten the smartPAD holder on the door of the robot controller or on the
wall. (>>> 6.4 "Fastening the KUKA smartPAD holder (optional)"
Page 101)
Connector pin
allocation X19
3. Carry out a ground conductor check for the entire industrial robot in
accor-dance with DIN EN 60204-1.
Description The robot controller is connected to the mains via a Harting connector X1.
Description To prevent the batteries from discharging before the controller has been start-
ed up for the first time, the robot controller is supplied with connector X305
dis-connected from the CCU.
Procedure Plug connector X305 into the CCU.
Procedure 1. Configure connector X11 in accordance with the system and safety con-
Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
Installation of KSS/VSS 8.2 or higher
This is the case if KSS/VSS 8.2 or higher is installed without KSS/VSS
8.2 or higher already being present (because it has been uninstalled or
delet-ed or has never been installed).
The hard drive has been exchanged.
A device has been replaced by a device of a different type.
More than one device has been replaced by a device of a different type.
One or more devices have been removed.
One or more devices have been added.
Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 without the
external safeguards being put into operation.
When Start-up mode is possible depends on the safety interface that is used.
Discrete safety interface
System Software 8.2 or earlier:
Start-up mode is always possible if all input signals at the discrete safety
interface have the state “logic zero”. If this is not the case, the robot con-
troller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the in-
puts there must also have the state “logic zero”.
System Software 8.3 or higher:
Start-up mode is always possible. This also means that it is
independent of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options:
The states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection to
a higher-level safety system exists or is established.
In Start-up mode, the system switches to the following simulated input image:
Function The smartPAD is the teach pendant for the industrial robot. The smartPAD has
all the operator control and display functions required for operating and pro-
gramming the industrial robot.
The smartPAD has a touch screen: the smartHMI can be operated with a fin-
ger or stylus. An external mouse or external keyboard is not necessary.
Overview
Item Description
1 Button for disconnecting the smartPAD
Item Description
3 EMERGENCY STOP button. Stops the robot in hazardous situa-
tions. The EMERGENCY STOP button locks itself in place when
it is pressed.
4 Space Mouse: For moving the robot manually.
9 Status keys. The status keys are used primarily for setting param-
eters in technology packages. Their exact function depends on
the technology packages installed.
10 Start key: The Start key is used to start a program.
11 Start backwards key: The Start backwards key is used to start a
program backwards. The program is executed step by step.
12 STOP key: The STOP key is used to stop a program that is run-
ning.
13 Keyboard key
Displays the keyboard. It is generally not necessary to press this
key to display the keyboard, as the smartHMI detects when key-
board input is required and displays the keyboard automatically.
Overview
Center position
Enabling Panic position
switch The enabling switch must be held in the center position
in operating modes T1 and T2 in order to be able to jog
the manipulator.
In the operating modes Automatic and Automatic Exter-
nal, the enabling switch has no function.
USB connec- The USB connection is used, for example, for archiving
and restoring data.
tion Only for FAT32-formatted USB sticks.
10 Maintenance
Description Maintenance work must be performed at the specified maintenance intervals
after commissioning at the customer’s plant.
Maintenance
symbols
Oil change
Tighten screw/nut
Clean component
Exchange battery
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
Once an activity from the maintenance list has been carried out, a visual in-
spection must be made, with special attention to the following points:
Check that fuses, contactors, plug-in connections and boards are fitted
se-curely.
Check cabling for damage.
Check PE equipotential bonding connection.
Check all system components for wear and damage.
the alarm space, the Cartesian or axis-specific alarm space can be violat-
ed.
Precondition The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The controller has been shut down.
The power cable is de-energized.
Work regulations The manufacturer’s instructions must be observed when using cleaning
11 Repair
Repair Repairs to the robot controller may only be carried out by KUKA customer
sup-port personnel or by customers who have taken part in a relevant course
of training held by KUKA Roboter GmbH.
Repairs within modules may only be carried out by specially trained KUKA
Ro-boter GmbH personnel.
Procurement The article numbers of the spare parts are listed in the spare parts catalog.
of spare parts KUKA Roboter GmbH supplies the following types of spare parts for repairs
to the robot controller:
New parts
Once the new part has been installed, the part that has been removed
can be disposed of.
Exchange parts
Once the exchange part has been installed, the part that has been re-
moved is returned to KUKA Roboter GmbH.
A “Robot Repair Card” is supplied with the exchange parts. The Re-
pair Card must be completed and returned to KUKA Roboter GmbH.
Connector pin
allocation
The industrial robot can be set to Start-up mode via the smartHMI
user interface. (>>> 8.11 "Start-up mode" Page 137) In this mode,
the manipulator can be moved in T1 mode without X11 being wired
up.
11.3 Exchanging the external fan
Preconditions The robot controller must be switched off and secured to prevent unau-
Description The internal fan is not installed in all cabinet variants. As as alternative to the
internal fan, a KPC cooling duct may be installed. (>>> 3.22 "Cabinet cooling"
Page 60) The internal fan is located in the lower left-hand corner of the control
cabinet.
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
files.
2. Turn off the robot controller using the main switch and take measures to
prevent it from being turned on again unintentionally.
3. Disconnect the power cable from the supply.
4. Unplug the power supply and all connections to the control PC.
5. Slacken the knurled nuts.
6. Remove the control PC and lift it out towards the top.
1 Knurled nut
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
Page 151)
2. Remote air duct, if present.
3. Remove the control PC cover.
4. Release and unplug the fan connector. Depending on the variant, the fan
connector is located either on the housing or directly on the motherboard.
on variant)
2 Outer fan grille 5 Fan identification plate
3 Fastening of fan grille (ex-
panding rivets)
8. If the fan is designed with an inner fan grille: fasten the inner fan grille
to the new fan with the expanding rivets.
The fan grille must be fastened to the side with the identification plate.
See (>>> Fig. 11-8 ).
Description Depending on the control PC variant, the LAN Dual NIC network card is per-
manently integrated into the motherboard. In this case, if the LAN Dual NIC
network card is defective, the entire control PC must be exchanged.
If the LAN Dual NIC network card is plugged onto the motherboard, it can be
exchanged separately.
Preconditions The robot controller must be switched off and secured to prevent unau-
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
Once the hard drive has been exchanged, the following options are
available in addition to configuration using WorkVisual:
Load the archive of the previous installation.
Restore the complete image using the KUKA Recovery Tool.
1 SATA connector
2 Power supply connector
3 Knurled screws on the underside
Fig. 11-11: Exchanging the hard drive, variant with retaining clip
1 SATA connection
2 Power supply connector
3 Retaining clip
Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
Installation of KSS/VSS 8.2 or higher
This is the case if KSS/VSS 8.2 or higher is installed without KSS/VSS
8.2 or higher already being present (because it has been uninstalled or
delet-ed or has never been installed).
The hard drive has been exchanged.
A device has been replaced by a device of a different type.
More than one device has been replaced by a device of a different type.
One or more devices have been removed.
One or more devices have been added.
Exchanging If a device is exchanged, at least one KCB, KSB or KEB device is replaced by
devices a device of the same type. Any number of KCB, KSB and KEB devices can be
exchanged until all devices in the KCB, KSB and KEB have been replaced si-
multaneously by devices of the same type. Simultaneous exchange of two
identical components of the KCB is not possible. Only one of the identical com-
ponents may be exchanged at any one time.
Connections
KPP 3 connec-
tions
Procedure 1. Unlock connectors X20 and X21 of the data cables. Unplug all connections
to the KPP.
3. Lift the KPP slightly, tilt the top forwards and lift the KPP out of the
support bracket.
4. Insert the new KPP into the support bracket, hook it on at the top and
tight-en the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable
la-beling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
configuration of the industrial robot must be configured using WorkVisual.
Connections
Procedure 1. Unlock connectors X20 and X21 of the data cables. Unplug all connections
to the KSP.
3. Lift the KSP slightly, tilt the top forwards and lift the KPP out of the
support bracket.
4. Insert the new KSP into the support bracket, hook it on at the top and
tight-en the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable
la-beling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
configuration of the industrial robot must be configured using WorkVisual.
Connections
Precondition The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable is de-energized.
Procedure 1. Unlock the data cable connectors. Unplug all connections to the CCU.
2. Remove the screw on the fastening plate and pull the plate with the
CCU out of the tab slots.
3. Check the new CCU for mechanical damage. Insert the fastening plate
with the CCU into the tab slots and screw it firmly in place.
4. Plug in all the connections in accordance with the connector and cable
la-beling. Lock the data cable connectors.
1 Tabs
2 Fastening screw
Standard connec-
tions
Extended
connections
Procedure 1. Unlock the data cable connectors. Unplug all connections to the SIB.
1 Fastening screw
2 Tabs
Connections
Procedure 1. Remove the screws from the lid of the RDC box.
The EDS memory is not removed and remains in the RDC box
when the RDC is exchanged.
5. Carefully remove the RDC module from the RDC box without tilting it.
6. Insert and fasten the new RDC module.
Variant Information
Batteries inside cabinet, behind (>>> 11.7.1 "Exchanging the bat-
cooling duct teries behind the cooling duct"
Page 171)
Batteries in cabinet door (>>> 11.7.2 "Exchanging the bat-
teries in the cabinet door"
Page 173)
Procedure 1. Shut down the robot controller by means of the main menu item Shut-
down. [Further information is contained in the operating and programming
instructions for the KUKA System Software.]
2. Turn off the robot controller and take measures to prevent it from being
turned on again unintentionally.
3. Disconnect the power cable from the supply.
A short -circuit or short to ground at the battery poles can trip the higher-
level fuse. The batteries have no fuse of their own. It must be ensured that
no short-circuit or short to ground is caused
at the battery poles.
8. Insert the new battery blocks and plug in the battery connection cables.
Storage
Procedure 1. Shut down the robot controller by means of the main menu item Shut-
down. [Further information is contained in the operating and programming
instructions for the KUKA System Software.]
2. Turn off the robot controller and take measures to prevent it from being
turned on again unintentionally.
3. Disconnect the power cable from the supply.
A short -circuit or short to ground at the battery poles can trip the higher-
level fuse. The batteries have no fuse of their own. It must be ensured that
no short-circuit or short to ground is caused
at the battery poles.
5. Remove both battery blocks from the battery holder in the cabinet door.
6. Insert the new battery blocks and plug in the battery connection cables.
12 Troubleshooting
Overview
CIB ent
Check fuse F308
In the case of external
supply via X308: check
external supply voltage
(rated voltage 24 V)
On = supply voltage present -
14 L/A Green On = physical connec- -
L/A Green tion
L/A Green Off = no physical con-
nection. Network cable
not plugged in.
Flashing = data traffic on
the line
15 STA1 (CIB) Orange Off = no supply voltage Check fuse F17.3
μC I/O node present If the LED PWR/3.3V
lights up, exchange the
CCU module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU module
nal)
16 STA1 (PMB) Orange Off = no supply voltage Check infeed at X1
μC USB present If the LED PWR/5V lights
up, exchange the CCU
module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU module
nal)
Overview
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
Overview
Overview
Fig. 12-4
LED1 = on
Controller is not in Automatic mode
Error states
Motherboards The following motherboard variants can be installed in the control PC:
D2608-K
D3076-K
D3236-K
Overview
Yellow = 1000 Mb
Overview
Yellow = 1000 Mb
Overview
Yellow = 1000 Mb
Standard
SIB ent
On = supply voltage present -
4 RUN Green On = operational (normal -
EtherCat state)
Safety nodes Off = Init (after switching on) -
Flashing at 2.5 Hz = Pre-Op -
(intermediate state on
startup)
Single signal = Safe Op -
Flashing at 10 Hz = boot (for -
firmware update)
Extended
The semiconductor fuses are not rated for frequent use and should
not be tripped intentionally, as this will reduce their service life.
Standard SIB
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
Extended SIB
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
Description The KSP LED display consists of the following LED groups:
KSP device status
Axis control
Communication status
If faults occur during the initialization phase, the middle axis control LEDs
flash. All other LEDs are off. The red axis control LED is lit continuously and
the green axis control LED flashes at 2 to 16 Hz, followed by a pause.
If defective firmware is detected during the initialization phase, the red
device status LED is lit and the green device status LED is dimmed.
Precondition
The robot controller is energized (50 -600 V) when it is
switched on. This voltage can cause life-threatening inju-
ries on contact. Work and measurements on the electrical equipment may
only be carried out by specially trained personnel.
Overview
status
2 LED group: KSP device status
Device status
Red LED Green LED Meaning
Off Off No power supply to the control elec-
tronics
On Off Fault in the KSP
Communication The green communication LEDs indicate the status of the bus connection.
Description The KPP LED display consists of the following LED groups:
Power supply
KPP device status
Axis control
Communication status
If faults occur during the initialization phase, the middle axis control LEDs
flash. All other LEDs are off. The red axis control LED is lit continuously and
the green axis control LED flashes at 2 to 16 Hz, followed by a pause.
If defective firmware is detected during the initialization phase, the red
device status LED is lit and the green device status LED is dimmed.
Precondition
The robot controller is energized (50 -600 V) when it is
switched on. This voltage can cause life-threatening inju-
ries on contact. Work and measurements on the electrical equipment may
only be carried out by specially trained personnel.
Overview
status
2 LED group: KPP device status 4 LED group: axis control
The green communication LEDs indicate the status of the bus connection:
Communication
LED Description
On Connected, no data transfer
Flashing Connected, data transfer
Off No connection
Description The LED display on the KPP indicates the communication status of the bus
connection.
Precondition
The robot controller is energized (50 -600 V) when it is
switched on. This voltage can cause life-threatening inju-
ries on contact. Work and measurements on the electrical equipment may
only be carried out by specially trained personnel.
Overview
Communication The green communication LEDs indicate the status of the bus connection:
LED Description
On Connected, no data transfer
Flashing Connected, data transfer
Off No connection
13.1 Decommissioning
Description This section describes all the work required for decommissioning the robot
controller if the robot controller is to be removed from the system. After decom-
missioning, it is prepared for storage or for transportation to a different loca-
tion.
Following its removal, the robot controller may only be transported with lifting
tackle and a fork lift truck or pallet truck.
Precondition The removal site must be accessible with a crane or with a fork lift truck for
transportation.
The crane and fork lift truck have an adequate carrying capacity.
There is no hazard posed by system components.
13.2 Storage
Preconditions If the robot controller is to be put into long-term storage, the following points
must be observed:
The place of storage must be as dry and dust-free as possible.
Avoid temperature fluctuations.
Avoid wind and drafts.
Avoid condensation.
Observe and comply with the permissible temperature ranges for
storage. (>>> 4 "Technical data" Page 63)
Select a storage location in which the packaging materials cannot be
dam-aged.
Only store the robot controller indoors.
Procedure 1. Clean robot controller. No dirt may remain on or in the robot controller.
2. Inspect the robot controller, both internally and externally, for damage.
3. Remove batteries and store in accordance with the manufacturer’s
instruc-tions.
4. Remove any foreign bodies.
5. Remove any corrosion expertly.
6. Attach all covers to the robot controller and check that the seals are
cor-rectly in place.
7. Seal off electrical connections with suitable covers.
8. Cover the robot controller with plastic film and seal it against
dust. If necessary, add a desiccant beneath the sheeting.
13.3 Disposal
When the robot controller reaches the end of its useful life, it can be disman-
tled, and the materials can be disposed of properly by type.
The following table provides an overview of the materials used in the robot
controller. Some of the plastic components are marked with a material desig-
nation and must be disposed of accordingly.
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Index
Numbers Connector pin allocation X66 119 Connector pin
2004/108/EC 95 allocation X7.1 and X7.2 30 Connector pin
2006/42/EC 95 allocation X7.1, X7.2 and X7.3 31 Connector
24 V external power supply pin allocation, heavy-duty robot 29 Control PC
21 89/336/EEC 95 95/16/EC 15, 17
95 Control PC components, exchanging 151
97/23/EC 95 Control PC, exchanging 151
Control PC, functions 18
A Control unit 64
Accessories 15, 73 Controller state 184
Altitude 64 Controller System Panel 15, 20
Ambient temperature 63 Controller System Panel LED display 183
ANSI/RIA R.15.06-2012 96 Controller System Panel LED error display 185
Applied norms and regulations 95 Cooling circuits 60
Automatic mode 92 Counterbalancing system 93
Axis range 74 CSP 10, 20
Axis range limitation 84 CSP LED display 183
Axis range monitoring 84 CSP LED error display 185
CSP overview 20
B Customer equipment 61
Basic data 63
Batteries 15, 21 D
Batteries behind the cooling duct, Danger zone 75
exchanging 171 Data cables 24, 134
Batteries, exchanging 171 Declaration of conformity 74
Battery discharge protection, reversing 136 Declaration of incorporation 73, 74
BRM10 Decommissioning 94, 205
Brake defect 86 defective fuses 181, 192
Brake release device 84 Dimensions of boreholes 69
Braking distance 74 Dimensions of robot controller 66
Bus devices 21 Dimensions, smartPAD holder 68
Disposal 94, 205
C Documentation, industrial robot 9
Cabinet Control Unit 15, 18 Drive controller 15
Cabinet Control Unit LED display 177 Drive power supply 15
Cabinet Control Unit, exchanging 163 Dual NIC 10
Cabinet Control Unit, fusing 181 Dynamic testing 110
Cabinet cooling 60
Cabinet Interface Board E
18 Cabinet type 63 Cable EA 11
lengths 65, 101 EC declaration of conformity 74
CCU 10, 18 EDS 10
CCU functions 18 EDS cool 10
CCU LED display, overview 177 Electromagnetic compatibility (EMC) 96
CE mark 74 Electromagnetic compatibility, EMC 97
Charge 21 EMC 10
CIB 10, 18 EMC Directive 74, 95
CIP Safety 10 EMD 10
CK 10 EMERGENCY STOP 140
Cleaning work 93 EMERGENCY STOP device 80, 81, 86
Configuration of cooling circuit 61 EMERGENCY STOP devices to X11 108
Connecting cables 15, 73 EMERGENCY STOP wiring example 108
Connecting cables, connecting 133 EMERGENCY STOP, external 81, 88
Connection conditions 100 EMERGENCY STOP, local 88
Connection manager 139 EN 60204-1 + A1 96
Connection panel 15 EN 61000-6-2 96
Connector pin allocation X11 104 EN 61000-6-4 + A1 96
Connector pin allocation X20 27, 28 EN 614-1 96
H L
Handling equipment 127 Labeling 85
Hard drive, exchanging 155 LAN Dual NIC network card, exchanging 154
Hazardous substances 93 LAN Onboard LED display 186, 187
HMI 10 LED group KPP axis control 195
Humidity class 64 LED group KPP communication 195, 196
LED group KPP device status 195
I LED group KPP power supply 195
Identification plate 141 LED group KSP axis control 194
Industrial robot 15, 73 LED group KSP communication 194
Infeed 24 LED group KSP device status 193
Installation, KUKA System Software 176 Liability 73
Intended use 13, 73 Lifting frame 125
Interfaces, connection panel 24 Linear unit 73
Interfaces, control PC 55, 185 Low Voltage Directive 74 Low-
Interfaces, motherboard D2608-K 56 voltage power supply unit 15, 21
Low-voltage power supply unit, exchanging Permissible tolerance of rated voltage 63, 100
Personnel 76
174 M
PFH values 122
Machine data 89 PL 122
Machinery Directive 74, Planning 97
95 Mains filter 21 Plant integrator 76
Mains frequency 63, 100 Plates and labels 69
Mains-side fusing 63, 100 PLC 11
Maintenance 92, 143, 185 PMB 18
Maintenance symbols 143 Positioner 73
Manipulator 11, 15, 73, 75 Power cable 24
Manual mode 91 Power cable, connecting 135
Material designation 206 Power failure 21
Mechanical axis range limitation 84 Power Management Board 18
Mechanical end stops 83 Power supply connection X1 Harting connector
Minimum clearances, robot controller 102
67 Mode selection 78, 79 Power supply connection, technical data 63,
Monitoring, velocity 83 100 Power supply with battery backup 19
Motherboard battery, exchange Power supply without battery backup 19
154 Motherboard D2608-K 56 Power switched off 21
Motherboard D3076-K 57, 58 Pressure Equipment Directive 93, 95
Motherboard D3236-K 58, 59 Pressure relief plug, exchanging 175
Motherboard, exchange 154 Preventive maintenance work 93
Motherboards 55, 185 Motor cables Procurement of spare parts 147
24 Product description 15 Protection
Motor connector X20 27, 28 rating 63
Motor connector Xxx 26 Protective equipment 83
Multiple connector X81 38 Purpose 13
N Q
NA 11 QBS 11
O R
Operation 139 Rated supply voltage 63, 100
Operator 77 RDC 11
Operator safety 78, 80, 86 RDC cool 11
Operator safety acknowledgement 122 RDC functions 20
Options 15, 73 RDC LED display, overview 182
Overload 86 Reaction distance 74
Overview of robot controller 15 Recommissioning 88, 131
Overview of the industrial robot 15 Release device 84
Overview, start-up 131 Repair 92, 147
Resolver cable, length difference 65, 101
P Resolver Digital Converter 19
Palletizing robot, connector pin allocation Resolver Digital Converter, exchanging 169
X7.1 37 Resolver Digital Converter, LED display 182
Palletizing robot, connector pin allocation Robot controller 15, 73
X7.1 and X7.2 38 Robot controller stacked 99
Palletizing robot, external axes 1 and 2 38 Robot controller, cleaning 146
Palletizing robot, external axis 1 37 Robot controller, installing 132
Panic position 82 RTS 11
PC fan, exchanging 152
PE cables 24 S
PE equipotential bonding 120 Safe operational stop 75, 82
PE equipotential bonding, connecting Safeguard to X11 108
135 PELV 11 Safeguards, external 85
PELV power supply unit 65, Safely isolated 65, 101
101 Performance level 122 SafeOperation via Ethernet safety interface 116
Performance Level 78 Safety 73
Peripheral cables 24 Peripheral Safety controller 79
contactor 90 Safety functions 78, 86
Safety functions, Ethernet safety interface 112 Start key 140, 141
Safety functions, overview 78 Start-up 88, 131
Safety gate, wiring example 109 Start-up mode 90, 137
Safety instructions 9 Start-up overview 131
Safety Interface Board 15, 19, 65 Safety Status keys 140
Interface Board, exchanging 166 Safety STOP 0 74, 76
Interface Board, fuses 191 Safety STOP 1 74, 76
Interface Board, LED display 188 Safety STOP 2 74, 76
interface X11, description 103 Safety of Stop category 0 76
machinery 95 Safety options 75 Stop category 1 76
Stop category 2 76
Safety STOP 0 75 STOP key 140
Safety STOP 1 75 Stop reactions 78
Safety STOP 2 75 Stopping distance 74, 77
Safety STOP 0 75 Storage 94, 205
Safety STOP 1 75 Storage of batteries 173
Safety STOP 2 75 Support request 207
Safety stop, external 83 Swing range for cabinet door 68
Safety zone 75, 77 Switching on the robot controller 138
Safety, general 73 System configuration, modifying 122, 137, 156
SATA connections 11 System integrator 74, 76, 77
Semiconductor fuse 191
Service life 75 T
Service, KUKA Roboter 207 T1 76
SG FC 11 T2 76
SIB 11, 19, 65 Target group 13
SIB description 19 Teach pendant 15, 73
SIB functions 19 Technical data 63
SIB inputs 66 Technology cabinet 69
SIB LED display, overview 188 Terms used 10
SIB outputs 65 Terms used, safety 74
SIB relay outputs, checking 145 Test output A 105, 107
SIB wiring 103 Test output B 105, 107
SIB, safe input 109 Touch screen 139
SIB, safe output 111 Trademarks 9
Signal “Peri enabled” 106 Training 13
Simulation 92 Transportation 87, 125
Single connectors X7.1 to X7.4 38 Transportation by fork lift truck 126
Single connectors X7.1 to X7.8 46 Transportation using fork slots 127
Single point of control 94 Transportation with standard cabinet base 127
SION 11 Transportation with transformer 127
Sleep mode, CSP 185 Transportation, lifting tackle 125
Slot assignment, motherboard D2608-K 56 Transportation, pallet truck 128
Slot assignment, motherboard D3076-K 58 Transportation, set of rollers 129
Slot assignment, motherboard D3236 59 Troubleshooting 177
smartPAD 75, 87, 139 Turn-tilt table 73
smartPAD cable extensions 65, 101
smartPAD holder, fastening 134 U
smartPAD, plugging in 134 US1 11
Software 15, 73 US2 11, 90
Software limit switches 83, 86 USB 11
SOP 11 USB connection 141
Sound level 63 Use, contrary to intended use 73
Space for integration of customer options 61 Use, improper 73
Space Mouse 140 User 75, 76
SPOC 94
SRM 11 V
SSB 11 Velocity monitoring 83
Standard SIB, connections 166 Vibration resistance 64
Standard SIB, fuses 192
Start backwards key 140
W
Warnings 9
Weight 63
Wiring example X11 148
Working range limitation 84
Workspace 74, 77
X
X11, configuring 136
X11, contact diagram 108
X19 connector pin allocation 135
X20, palletizing robot, 4 axes 33
X20, palletizing robot, 5 axes 35
X20.1 and X20.4, palletizing robot, 5 axes 34
X20.1 connector pin allocation 29
X20.4 connector pin allocation 29
X21 connector pin allocation 134
X66 119
X7.1 to X7.3, 3 axes 47
X7.1 to X7.4, 4 axes 48
X7.1 to X7.5, 5 axes 49
X7.1 to X7.6, 6 axes 50
X7.1 to X7.7, 7 axes 52
X7.1 to X7.8, 8 axes 54
X7.1, connector pin allocation 30
X8, palletizing robot, 4 axes 32
X81, 3 axes 39
X81, 4 axes 36, 40
X81, X7.1 and X7.2, 6 axes 42
X81, X7.1 to X7.3, 7 axes 43
X81, X7.1 to X7.4, 8 axes 44
X81, X7.1, 5 axes 41
X82, 8 axes 37