Controller

KR C5 micro
Assembly Instructions

Issued: 21.09.2020
MA KR C5 micro V3
KUKA Deutschland GmbH
KR C5 micro

© Copyright 2020
KUKA Deutschland 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 Deutschland 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 soft-
ware 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 regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation

Publication: Pub MA KR C5 micro (PDF) en

PB11486

Book structure: MA KR C5 micro V3.1

BS6146

Version: MA KR C5 micro V3

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Contents

1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Industrial robot documentation.............................................................................. 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Trademarks............................................................................................................ 8
1.5 Terms used............................................................................................................ 8

2 Product description................................................................................. 11
2.1 Description of the industrial robot......................................................................... 11
2.2 Overview of the robot controller........................................................................... 11
2.2.1 Control box with “Basic” system board................................................................ 12
2.2.2 Drive box............................................................................................................... 13
2.3 Description of interfaces........................................................................................ 13
2.4 Controller System Panel....................................................................................... 14
2.5 Cooling................................................................................................................... 14
2.6 Intended use and misuse...................................................................................... 15

3 Safety......................................................................................................... 17
3.1 General.................................................................................................................. 17
3.1.1 Liability................................................................................................................... 17
3.1.2 EC declaration of conformity and declaration of incorporation............................ 17
3.1.3 Terms in the “Safety” chapter............................................................................... 18
3.2 Personnel............................................................................................................... 20
3.3 Workspace, safety zone and danger zone........................................................... 22
3.3.1 Determining stopping distances............................................................................ 22
3.4 Triggers for stop reactions: KSS........................................................................... 22
3.5 Triggers for stop reactions: VSS........................................................................... 23
3.6 Safety functions..................................................................................................... 24
3.6.1 Overview of the safety functions.......................................................................... 24
3.6.2 Safety controller..................................................................................................... 24
3.6.3 Operating mode selection: KSS............................................................................ 25
3.6.4 Operating mode selection: VSS............................................................................ 26
3.6.5 “Operator safety” signal: KSS............................................................................... 27
3.6.6 “Operator safety” signal: VSS............................................................................... 28
3.6.7 EMERGENCY STOP device................................................................................. 28
3.6.8 Logging off from the higher-level safety controller............................................... 28
3.6.9 External EMERGENCY STOP device.................................................................. 29
3.6.10 Enabling device..................................................................................................... 29
3.6.11 External enabling device....................................................................................... 31
3.6.12 Velocity monitoring in T1....................................................................................... 31
3.7 Additional protective equipment............................................................................ 31
3.7.1 Jog mode............................................................................................................... 31
3.7.2 Software limit switches.......................................................................................... 32
3.7.3 Mechanical end stops........................................................................................... 32
3.7.4 Mechanical axis limitation (optional)..................................................................... 32
3.7.5 Options for moving the manipulator without drive energy................................... 33
3.7.6 Labeling on the industrial robot............................................................................ 33

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3.7.7 External safeguards............................................................................................... 34

3.8 Overview of operating modes and safety functions: KSS................................... 34
3.9 Overview of operating modes and safety functions: VSS................................... 35
3.10 Safety measures.................................................................................................... 35
3.10.1 General safety measures...................................................................................... 35
3.10.2 IT security.............................................................................................................. 36
3.10.3 Transportation........................................................................................................ 37
3.10.4 Start-up and recommissioning: KSS/VSS............................................................. 37
3.10.4.1 Checking machine data and safety configuration................................................ 39
3.10.4.2 Start-up mode........................................................................................................ 41
3.10.5 Manual mode......................................................................................................... 43
3.10.6 Simulation.............................................................................................................. 44
3.10.7 Automatic mode..................................................................................................... 44
3.10.8 Maintenance and repair........................................................................................ 44
3.10.9 Decommissioning, storage and disposal.............................................................. 46
3.10.10 Safety measures for single point of control......................................................... 46

4 Technical data.......................................................................................... 49
4.1 Basic data.............................................................................................................. 49
4.2 Dimensions............................................................................................................ 51
4.3 Minimum clearances, robot controller................................................................... 51
4.4 Minimum clearances for installation in an external housing................................ 52
4.5 Plates and labels................................................................................................... 53
4.6 REACH duty to communicate information acc. to Art. 33................................... 55

5 Planning.................................................................................................... 57
5.1 Overview of planning............................................................................................. 57
5.2 Electromagnetic compatibility (EMC).................................................................... 57
5.3 Installation conditions............................................................................................ 58
5.4 Installation with holders......................................................................................... 62
5.5 PE equipotential bonding...................................................................................... 64
5.6 Connection conditions........................................................................................... 65
5.7 Routing the connecting cables.............................................................................. 66
5.8 Power supply connection...................................................................................... 67
5.9 Overview of interfaces........................................................................................... 67
5.9.1 XGSD interface, SD card...................................................................................... 71
5.9.2 USB interface........................................................................................................ 71
5.9.3 Interfaces XF1 - XF8............................................................................................. 71
5.9.3.1 KSI interface.......................................................................................................... 72
5.9.3.2 KONI interface....................................................................................................... 72
5.9.3.3 Daisy chain interface............................................................................................. 73
5.9.3.4 KLI interfaces......................................................................................................... 73
5.9.3.5 KLI IT interface...................................................................................................... 73
5.9.3.6 KEI interface.......................................................................................................... 73
5.9.4 XGDP interface...................................................................................................... 74
5.9.5 XG12 digital I/O interfaces.................................................................................... 74
5.9.6 XD12 and XD12.1 power supply interfaces......................................................... 76
5.9.7 XD2 UPS interface................................................................................................ 76
5.9.8 Safety interfaces.................................................................................................... 79

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5.9.8.1 Interface XG58, external enabling switch............................................................. 79

5.9.8.2 Safety interface XG11.1........................................................................................ 81
5.9.8.3 Wiring examples for safe inputs and outputs....................................................... 82
5.9.9 Safety functions via Ethernet safety interface (optional)..................................... 85
5.9.10 XG33 Fast Measurement inputs........................................................................... 89
5.9.10.1 Power supply for Fast Measurement.................................................................... 90
5.9.11 Connecting data cables XF21............................................................................... 91
5.9.12 XD20.1 and XD20.2 motor interface.................................................................... 92
5.10 Performance level.................................................................................................. 93
5.10.1 PFH values of the safety functions...................................................................... 93

6 Transportation.......................................................................................... 95
6.1 Transportation with trolley..................................................................................... 95

7 Start-up and recommissioning............................................................... 97

7.1 Start-up overview................................................................................................... 97
7.2 Installing the robot controller................................................................................. 99
7.3 Connecting the connecting cables and ground conductor................................... 100
7.4 Plugging in the KUKA smartPAD.......................................................................... 101
7.5 Connecting the mains power supply.................................................................... 101
7.6 Connecting the UPS.............................................................................................. 101
7.7 Configuring and connecting safety interface XG11.1........................................... 102
7.8 Configuring and connecting safety interface XG58.............................................. 102
7.9 Switching on the robot controller.......................................................................... 102
7.10 Concluding work.................................................................................................... 103

8 Operation.................................................................................................. 105
8.1 Switching on the robot controller.......................................................................... 105
8.2 Function of soft power button............................................................................... 105

9 Maintenance.............................................................................................. 107
9.1 Cleaning the robot controller................................................................................. 108

10 Repair........................................................................................................ 111
10.1 Exchanging the strain relief device....................................................................... 111
10.1.1 Installing the strain relief device........................................................................... 111
10.1.2 Removing the strain relief device......................................................................... 112
10.1.3 Concluding work.................................................................................................... 112
10.2 Exchanging the Mounting brackets 19" frame..................................................... 112
10.2.1 Installing the Mounting brackets 19" frame.......................................................... 113
10.2.2 Removing the Mounting brackets 19" frame........................................................ 113
10.2.3 Concluding work.................................................................................................... 114
10.3 Exchanging the SSD hard drive........................................................................... 114
10.3.1 Removing the SSD hard drive.............................................................................. 115
10.3.2 Installing the SSD hard drive................................................................................ 115
10.3.3 Concluding work.................................................................................................... 115
10.4 Exchanging the motherboard battery.................................................................... 116
10.4.1 Removing the housing cover................................................................................ 117
10.4.2 Removing the motherboard battery...................................................................... 118
10.4.3 Inserting the motherboard battery......................................................................... 118
10.4.4 Installing the housing cover.................................................................................. 119

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10.4.5 Concluding work.................................................................................................... 120

10.5 Exchanging the incoming supply fuse.................................................................. 120
10.5.1 Exchanging the incoming supply fuse.................................................................. 121
10.5.2 Concluding work.................................................................................................... 121

11 Troubleshooting....................................................................................... 123
11.1 KSP warning messages........................................................................................ 123
11.2 Controller System Panel LED display.................................................................. 125
11.3 Controller System Panel LED error display......................................................... 127
11.4 Creating or restoring a KR C5 recovery image................................................... 128
11.4.1 Creating a recovery image.................................................................................... 129
11.4.2 Restoring a recovery image.................................................................................. 129
11.4.3 Terminating KUKA.Recovery................................................................................. 130
11.4.4 Concluding work.................................................................................................... 131
11.5 System board LED fault indicator......................................................................... 131

12 Decommissioning, storage and disposal............................................. 133

12.1 Decommissioning................................................................................................... 133
12.1.1 Concluding work.................................................................................................... 133
12.2 Storage.................................................................................................................. 133
12.3 Disposal................................................................................................................. 134

13 Appendix................................................................................................... 137
13.1 Applied standards and regulations....................................................................... 137

14 KUKA Service........................................................................................... 139

14.1 Requesting support............................................................................................... 139
14.2 KUKA Customer Support...................................................................................... 139

Index 141

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Introduction
1 Introduction

1.1 Target group

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

For optimal use of KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2 (if used)
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts overview in KUKA Xpert
Each of these sets of instructions is a separate document.

1.3 Representation of warnings and notes

Safety

These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.

WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.

CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.

NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.

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Introduction KR C5 micro

These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:
SAFETY INSTRUCTION
The following procedure must be followed exactly!

Procedures marked with this warning must be followed exactly.

Notices

These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.

1.4 Trademarks

• Windows is a trademark of Microsoft Corporation.

• EtherCAT® is a registered trademark and patented tech-

nology, licensed by Beckhoff Automation GmbH, Germany.

• CIP Safety® is a trademark of ODVA.

1.5 Terms used

The overview may contain terms symbols that are not relevant for this
document.

Term Description

Br M{Number} Brake Motor{Nummer}

Daisy chain Network technology in which multiple hardware components are

connected in series via a bus system.

EDS Electronic Data Storage

(memory card)

EDS cool Electronic Data Storage cool

Memory card with extended temperature range

EMD Electronic Mastering Device

EMC Electromagnetic compatibility

EtherNet/IP Ethernet Industrial Protocol

EtherNet/IP is an Ethernet-based field bus (Ethernet interface).

Main switch The term “main switch” used in this documentation refers to a de-
vice switch as defined by relevant standards, as it has no grid iso-
lation function.

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Introduction
HMI Human-Machine Interface
KUKA.HMI is the KUKA user interface.

IFBstd “Standard” interface board

The interface board provides non-safe digital I/Os.

KCB KUKA Controller Bus

KEB KUKA Extension Bus

KEI KUKA EtherCAT Interface

KLI KUKA Line Interface

Connection to higher-level control infrastructure (PLC, archiving)

KRL KUKA Robot Language

KUKA robot programming language

KSB KUKA System Bus

Field bus for internal networking of the controllers

KSI KUKA Service Interface

Interface on the CSP on the control cabinet or robot controller
The WorkVisual PC can either connect to the robot controller via
the KLI or it can be plugged into the KSI.

KSP KUKA Servo Pack

drive controller

KSS KUKA System Software

KUKA smartPAD-2 see “smartPAD”

M{Number} Motor {Number}

Manipulator The robot arm and the associated electrical installations

mini CSP mini Controller System Panel

Display and operator control element for the robot controller

NA North America

PELV Protective Extra Low Voltage

External 24 V power supply

PoE Power over Ethernet

QBS Operator safety acknowledgement signal

RDC Resolver Digital Converter

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).

RDC cool Resolver Digital Converter

Resolver Digital Converter with extended temperature range

SION Safety Input/Output Node

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smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the manipulator.

SOP Safe Operation

Safety option with software and hardware components for configur-
ing safe monitoring functions in addition to the standard safety func-
tions.

SSD Solid State Drive

Hard drive

PLC Programmable Logic Controller

Used in systems as a higher-level master module in the bus sys-
tem.

System board The system board constitutes the control computer.

The following models are available:

• SYBbasic: “Basic” system board

• SYBperf: “Performance” system board
The designation “system board” refers to both models unless an ex-
plicit distinction is made.

US1 Load voltage (24 V) not switched

US2 Load voltage (24 V) switched. Deactivates actuators, for example,

when the drives are deactivated

USB Universal Serial Bus

Bus system for connecting additional devices to a computer

UPS Uninterruptible power supply

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Product description
2 Product description

2.1 Description of the industrial robot

The industrial robot consists of the following components:

• Manipulator
• Robot controller
• smartPAD teach pendant
• Connecting cables
• Software
• Options, accessories

Fig. 2-1: Example of an industrial robot

1 Manipulator
2 Teach pendant, KUKA smartPAD-2
3 Connecting cable / smartPAD
4 Robot controller
5 Connecting cable / data cable
6 Connecting cable / motor cable

2.2 Overview of the robot controller

The robot controller is used for controlling the following systems:

• KUKA small robots
The robot controller consists of the following components:
• Control unit
• Power unit
• Safety logic
• smartPAD teach pendant
• Connection panel

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Fig. 2-2: Overview

1 Control unit (control box)

2 Power unit (drive box)

2.2.1 Control box with “Basic” system board

The control box consists of the following components:

Fig. 2-3: Control box with mini CSP

1 mini CSP
2 Holder for button cell
3 Cover for SSD
4 SSD (optional)
5 System board (“Basic” system board illustrated here)
The system board is connected to the IFBstd interface board via a
ribbon cable and to the KSP via the ICT plug connection. The KSP
provides the supply voltage of the system board.
6 Control unit carrier plate

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Product description
7 IFBstd interface board
The IFBstd interface board is supplied with the supply voltage via
the system board.

2.2.2 Drive box

WARNING
Danger to life and limb due to opening the power unit
The power unit of the robot controller must not be opened. Death, se-
vere injuries or damage to property may result.
• The power unit of the robot controller must not be opened.

Description

The drive box consists of the following components:

• Fan
• Mains filter (interference suppressor filter) suppresses interference vol-
tages on the power cable
• Brake resistor
• Heat sink
• KSP-300 consisting of:
‒ FCU-300
‒ SCU-6-1S

Functions

The drive box performs the following functions:

• Generation of the intermediate circuit voltage and system voltage
• Control of the motors
• Control of the brakes
• Checking of intermediate circuit voltage in braking mode

NOTICE
Further information about the interfaces and the connection panels can
be found in the “Planning” chapter. (>>> 5.9 "Overview of interfaces"
Page 67)

2.3 Description of interfaces

Overview

The connection panel of the robot controller consists as standard of con-

nections for the following cables:
• Device connection cable
• UPS/battery box
• Motor cable, data cable
• Safety interfaces
• smartPAD cable
• Peripheral cables

Notice

The following safety interfaces are available:

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• Discrete safety interface XG11.1

NOTICE
Further information about the interfaces and the connection panels can
be found in the “Planning” chapter. (>>> 5.9 "Overview of interfaces"
Page 67)

2.4 Controller System Panel

Description

The Controller System Panel (mini CSP) is the display element for the op-
erating state and is connected to the system board.

Overview

Fig. 2-4: Controller System Panel LED arrangement

Item Element Color Meaning

1 LED1 White Operating mode LED (Test or
Automatic)
2 LED2 Green Operating status LED
3 LED3 Red Error LED
4 LED4 “soft White Sleep LED
power” button

2.5 Cooling

Description

The components of the control and power electronics are cooled with am-
bient air by 2 fans.

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Product description
Fig. 2-5: Cooling

1 Air inlet 2 Air outlet

2.6 Intended use and misuse

Use

The robot controller is intended solely for operating the following compo-
nents:
• KUKA industrial robots

Misuse

Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. It will result in the loss of warranty and liability
claims. KUKA is not liable for any damage resulting from such misuse.
This includes e.g.:
• Use as a climbing aid
• Operation outside the specified operating parameters
• Operation without the required safety equipment
• Transportation of persons and animals
• Outdoor operation.
• Use in a potentially explosive area
• Use in radioactive environments
• Operation in underground mining

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Safety
3 Safety

3.1 General

3.1.1 Liability

The device described in this document is either an industrial robot or a

component thereof.
Components of the industrial robot:

• Manipulator
• Robot controller
• Teach pendant
• Connecting cables
• External axes (optional)
e.g. linear unit, turn-tilt table, positioner
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial robot may constitute a risk to life and limb or cause damage to the
industrial robot and to other material property.
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons who
are fully aware of the risks involved in its operation. Use of the industrial
robot is subject to compliance with this document and with the declaration
of incorporation supplied together with the industrial robot. Any functional
disorders, especially those affecting safety, must be rectified immediately.

Safety information

Information about safety may not be construed against the manufacturer.

Even if all 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 au-
thorization of the manufacturer. Unauthorized modifications will result in
the loss of warranty and liability claims.
Additional components (tools, software, etc.), not supplied by the manufac-
turer, may be integrated into the industrial 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 in-
structions. These must also be observed.

3.1.2 EC declaration of conformity and declaration of incorporation

The industrial robot constitutes partly completed machinery as defined by

the EC Machinery Directive. The industrial robot may only be put into op-
eration if the following preconditions are met:

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• The industrial robot is integrated into a complete system.

or: The industrial robot, together with other machinery, constitutes a
complete system.
or: All safety functions and safeguards required for operation in the
complete machine as defined by the EC Machinery Directive have
been added to the industrial robot.
• The complete system complies with the EC Machinery Directive. This
has been confirmed by means of a conformity assessment procedure.

EC declaration of conformity

The system integrator must issue an EC declaration of conformity for the

complete system in accordance with the Machinery Directive. The EC dec-
laration of conformity forms the basis for the CE mark for the system. The
industrial robot must always be operated in accordance with the applicable
national laws, regulations and standards.
The robot controller has a CE mark in accordance with the EMC Directive
and the Low Voltage Directive.

Declaration of incorporation

The partly completed machinery is supplied with a declaration of incorpo-

ration in accordance with Annex II B of the Machinery Directive
2006/42/EC. The assembly instructions and a list of essential require-
ments complied with in accordance with Annex I are integral parts of this
declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly
completed machinery is not allowed until the partly completed machinery
has been incorporated into machinery, or has been assembled with other
parts to form machinery, and this machinery complies with the terms of
the EC Machinery Directive, and the EC declaration of conformity is
present in accordance with Annex II A.

3.1.3 Terms in the “Safety” chapter

STOP 0, STOP 1 and STOP 2 are the stop definitions according to

EN 60204-1:2018.
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.

User The user of the industrial robot can be the management, employer
or delegated person responsible for use of the industrial robot.

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 dur-
ing storage.

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Safety
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).

KSS KUKA System Software

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 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
stationary. If these are moved during the safe operational stop, a
safety 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 stationary at the time of triggering, thereby causing a safety
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
braking operation is carried out by the non-safety-oriented section
of the robot controller and monitored by the safety controller. As
soon as the manipulator has stopped, the safety controller deacti-
vates the drives and the power supply of 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
braking operation is carried out by the non-safety-oriented section
of the robot controller and monitored by the safety controller. The
drives remain activated and the brakes released. As soon as the
manipulator is at a standstill, 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 addi-
tional safe monitoring functions in addition to the standard safety
functions.
Example: SafeOperation

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smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot.
For robot controllers of the KR C5 series, the model smartPAD-2 is
used. This model has a number of variants, e.g. with different
lengths of connecting cables.

Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.

Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KSS), AUT EXT (KSS), EXT (VSS):
the drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 in this document.

Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KSS), AUT EXT (KSS), EXT (VSS):
the drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 - DRS in this document.

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 indus-
(plant integrator) trial 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)

VSS VW System Software

External axis Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. e.g. KUKA linear unit, turn-tilt table,
Posiflex

3.2 Personnel

The following persons or groups of persons are defined for the industrial
robot:

• User
• Personnel

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Safety
Qualification of personnel
Work on the system must only be performed by personnel that is able
to assess the tasks to be carried out and detect potential hazards.
Death, severe injuries or damage to property may otherwise result. The
following qualifications are required:
• Adequate specialist training, knowledge and experience
• Knowledge of the relevant operating or assembly instructions, knowl-
edge of the relevant standards
• 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.

• The user must carry out briefing at defined intervals.
• The user must comply with the regulations relating to personal protec-
tive equipment (PSA).

Personnel

Personnel must be instructed, before any work is commenced, in the type

of work involved and what exactly it entails as well as any hazards which
may exist. Instruction must be carried out regularly. Instruction is also re-
quired after particular incidents or technical modifications.
Personnel includes:

• System integrator
• Operators, subdivided into:
‒ Start-up, maintenance and service personnel
‒ Operating personnel
‒ Cleaning personnel

System integrator

The industrial robot is safely integrated into a complete system by the sys-
tem 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 EC declaration of conformity
• Attaching the CE mark
• Creating the operating instructions for the system

Operators

The operator must meet the following preconditions:

• The operator must be trained for the work to be carried out.
• Work on the system must only be carried out by qualified personnel.
These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are

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able to assess the work to be carried out and detect any potential
Safety

hazards.

3.3 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A work-

space must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone.
In the case of a stop, the manipulator and external axes (optional) are
braked and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). It must be safeguarded by
means of physical safeguards to prevent danger to persons or the risk of
material damage.

3.3.1 Determining stopping distances

The system integrator’s risk assessment may indicate that the stopping
distances must be determined for an application. In order to determine the
stopping 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 operating 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 repeated several times with a safety stop 0 and a safety stop 1. The
least favorable stopping distance is decisive.
A safety stop 0 can be triggered by a safe operational stop via the safety
interface, for example. If a safety option is installed, it can be triggered,
for instance, 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 de-
vice on the smartPAD, for example.

3.4 Triggers for stop reactions: KSS

Stop reactions of the industrial robot are triggered in response to operator

actions or as a reaction to monitoring functions and error messages. The
following table shows the different stop reactions according to the operat-
ing mode that has been set.
Trigger T1, T2 AUT, AUT EXT
Start key released STOP 2 -
STOP key pressed STOP 2
Drives OFF STOP 1
$MOVE_ENABLE input drops out STOP 2
Power switched off via main switch or STOP 0
device switch
Or power failure
Internal error in non-safety-oriented part STOP 0 or STOP 1
of the robot controller
(dependent on the cause of the error)

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Safety
Trigger T1, T2 AUT, AUT EXT
Operating mode changed during opera- Safety stop 2
tion
Safety gate opened (operator safety) - Safety stop 1
Enabling switch released (internal or ex- Safety stop 2 -
ternal enabling)
Internal enabling switch pressed down Safety stop 1 -
fully or error
External enabling switch pressed down Safety stop 2 -
fully or error
E-STOP pressed Safety stop 1
Error in safety controller or periphery of Safety stop 0
the safety controller
* In the KR C5 series, the “pressed down fully” position is not communica-
ted to the robot controller as a specific “panic position” signal for external
enabling, but only as “enabling not present”. This triggers a safety stop 2.

3.5 Triggers for stop reactions: VSS

Stop reactions of the industrial robot are triggered in response to operator

actions or as a reaction to monitoring functions and error messages. The
following table shows the different stop reactions according to the operat-
ing mode that has been set.
Trigger T1, T2 EXT
Start key released STOP 2 -
STOP key pressed STOP 2
Drives OFF STOP 1
Power switched off via main switch or STOP 0
device switch
Or power failure
Internal error in non-safety-oriented part STOP 0 or STOP 1
of the robot controller
(dependent on the cause of the error)
Operating mode changed during opera- Safety stop 2
tion
Safety gate opened (operator safety) - Safety stop 1
Enabling switch released (internal or ex- Safety stop 2 -
ternal enabling)
Internal enabling switch pressed down Safety stop 1 -
fully or error
External enabling switch pressed down Safety stop 2 -
fully or error
E-STOP pressed Safety stop 1
Error in safety controller or periphery of Safety stop 0
the safety controller
* In the KR C5 series, the “pressed down fully” position is not communica-
ted to the robot controller as a specific “panic position” signal for external
enabling, but only as “enabling not present”. This triggers a safety stop 2.

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3.6 Safety functions

3.6.1 Overview of the safety functions

The following safety functions are present in the industrial robot:

• Operating mode selection
• Operator safety (= connection for the monitoring of physical safe-
guards)
• EMERGENCY STOP device
• Enabling device
• Velocity monitoring in T1
The safety functions of the industrial robot meet the following require-
ments:
• Category 3 and Performance Level d in accordance with EN ISO
13849-1
The requirements are only met on the following condition, however:
• The EMERGENCY STOP device is pressed at least once every 12
months.
• The enabling device is checked at least once every 12 months.
(>>> "Function test" Page 30)

DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.

Integrate industrial robot into safety system of the overall system

During system planning, the safety functions of the overall system must
be planned and designed. Death, severe injuries or damage to property
may otherwise result.
• The industrial robot must be integrated into the safety system of the
overall system.

3.6.2 Safety controller

The safety controller is a unit inside the control PC. It links safety-relevant
signals 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

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Safety
3.6.3 Operating mode selection: KSS

Operating modes

The industrial robot can be operated in the following modes:

• Manual Reduced Velocity (T1)
• Manual High Velocity (T2)
• Automatic (AUT)
• Automatic External (AUT EXT)

Do not change the operating mode while a program is running. If the

operating mode is changed during program execution, the industrial ro-
bot is stopped with a safety stop 2.

Operating
Use Velocities
mode

• Program verification:
Programmed velocity, maxi-
For test operation,
mum 250 mm/s
T1 programming and
teaching • Jog mode:
Jog velocity, maximum
250 mm/s
• Program verification:
T2 For test operation Programmed velocity
• Jog mode: Not possible

For industrial robots • Program operation:

AUT without higher-level Programmed velocity
controllers • Jog mode: Not possible

For industrial robots • Program operation:

AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC • Jog mode: Not possible

Mode selector switch

The user can change the operating mode via the connection manager.
The connection manager is a view that is called by means of the mode
selector switch on the smartPAD.
The mode selector switch may be one of the following variants:
• With key
It is only possible to change operating mode if the key is inserted.
• Without key

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WARNING
Danger to life and limb due to mode selector switch without
access restriction
If the smartPAD is equipped with a mode selector switch without a key,
all persons can operate the mode selector switch, irrespective of their
field of activity or qualifications. Death, severe injuries or damage to
property may result.
• An additional device must be installed to ensure that the mode se-
lector switch can only be operated by a restricted group of people.
• The device itself must not trigger motions of the industrial robot or
other hazards.

3.6.4 Operating mode selection: VSS

Operating modes

The industrial robot can be operated in the following modes:

• Manual Reduced Velocity (T1)
• Manual High Velocity (T2)
• Automatic External (EXT)

Do not change the operating mode while a program is running. If the

operating mode is changed during program execution, the industrial ro-
bot is stopped with a safety stop 2.

Operating
Use Velocities
mode

• Program verification:
Programmed velocity, maxi-
For test operation,
mum 250 mm/s
T1 programming and
teaching • Jog mode:
Jog velocity, maximum
250 mm/s
• Program verification:
T2 For test operation Programmed velocity
• Jog mode: Not possible

For industrial robots • Program operation:

EXT with higher-level con- Programmed velocity
trollers, e.g. PLC • Jog mode: Not possible

Mode selector switch

The user can change the operating mode via the connection manager.
The connection manager is a view that is called by means of the mode
selector switch on the smartPAD.

Bypassing

In order to be able to move the manipulator in operating mode T1 or T2

with the safety gate open, the following keys are available:

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Safety
Active key Authorization
E2/E22 Authorization to move in T1 with the safety
gate open
E2/E22 and E7 Authorization to move in T2 with the safety
gate open

WARNING
Danger to life and limb of persons in danger zone in T2
In T2, the robot moves at the programmed velocity. Death, severe inju-
ries or damage to property may result.
• There must be no persons in the danger area.

Use E keys in a safety-conscious manner

Keys E2/E22 and E7 must be used in a safety-conscious manner.
Death, severe injuries or damage to property may otherwise result.
• It is the responsibility of the user or system integrator to determine
which key may be used and when. The applicable laws, regulations
and standards must be taken into consideration.
• The keys may only be used by qualified personnel.

Program execution
Jogging possible?
Active key Safety gate possible?
T1 T2 T1 T2
No key active Open No No No No
Closed Yes No Yes Yes
E2/E22 Open Yes No Yes No
Closed No No No No
E2/E22 and E7 Open Yes No No Yes
Closed No No No No

3.6.5 “Operator safety” signal: KSS

The “operator safety” signal is used for monitoring 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).
WARNING
Danger to life and limb due to resumed automatic operation with-
out adequate acknowledgement
Following loss of the “Operator safety” signal, it must not be possible to
restart automatic operation by merely closing the safeguard. Otherwise,
for example, the safety gate could close unintentionally, thereby causing
automatic operation to resume while there are persons in the danger
zone. Death, severe injuries or damage to property may result.
• Automatic operation must not be resumed until the safeguard has
been closed and the closing has been acknowledged.
• The acknowledgement must be designed in such a way that an ac-
tual check of the danger zone can be carried out first. Other ac-
knowledgement functions (e.g. an acknowledgement which is auto-
matically triggered by closure of the safeguard) are not permitted.

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3.6.6 “Operator safety” signal: VSS

The “Operator safety” signal is used for monitoring 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.
In Manual Reduced Velocity (T1) mode, operator safety can be bypassed
with the E2/E22 key.
In Manual High Velocity (T2) mode, operator safety can be bypassed with
the E2/E22+E7 key.
WARNING
Danger to life and limb due to resumed automatic operation with-
out adequate acknowledgement
Following loss of the “Operator safety” signal, it must not be possible to
restart automatic operation by merely closing the safeguard. Otherwise,
for example, the safety gate could close unintentionally, thereby causing
automatic operation to resume while there are persons in the danger
zone. Death, severe injuries or damage to property may result.
• Automatic operation must not be resumed until the safeguard has
been closed and the closing has been acknowledged.
• The acknowledgement must be designed in such a way that an ac-
tual check of the danger zone can be carried out first. Other ac-
knowledgement functions (e.g. an acknowledgement which is auto-
matically triggered by closure of the safeguard) are not permitted.

3.6.7 EMERGENCY STOP device

The EMERGENCY STOP device for the industrial robot is the EMERGEN-
CY STOP device on the smartPAD. The device must be pressed in the
event of a hazardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP device is
pressed:
• The manipulator and any external axes (optional) are stopped with a
safety stop 1.
Before operation can be resumed, the EMERGENCY STOP device must
be turned to release it.
WARNING
Danger to life and limb due to tools and equipment without EMER-
GENCY STOP
If tools and other equipment connected to the robot are not integrated
into the EMERGENCY STOP circuit, this can result in death, severe in-
juries or damage to property.
• Integrate tools and other equipment into the EMERGENCY STOP
circuit if they could constitute a potential hazard.

There must always be at least one external EMERGENCY STOP device

installed. This ensures that an EMERGENCY STOP device is available
even when the smartPAD is disconnected.
(>>> 3.6.9 "External EMERGENCY STOP device" Page 29)

3.6.8 Logging off from the higher-level safety controller

If the robot controller is connected to a higher-level safety controller, this

connection will inevitably be terminated in the following cases:

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Safety
• Switching off the voltage via the main switch or device switch of the
robot controller
Or power failure
• Shutdown of the robot controller via the smartHMI
• Activation of a WorkVisual project in WorkVisual or directly on the ro-
bot controller
• Changes to Start-up > Network configuration
• Changes to Configuration > Safety configuration
• I/O drivers > Reconfigure
• Restoration of an archive
Effect of the interruption:
• If a discrete safety interface is used, this triggers an EMERGENCY
STOP for the overall system.
• If the Ethernet interface is used, the KUKA safety controller generates
a signal that prevents the higher-level controller from triggering an
EMERGENCY STOP for the overall system.

Take Ethernet safety interface into consideration in risk assess-

ment
Failure to take the Ethernet safety interface into consideration in the risk
assessment may result in death, severe injuries or damage to property.
• In his risk assessment, the system integrator must take into consid-
eration whether the fact that switching off the robot controller does
not trigger an EMERGENCY STOP of the overall system could con-
stitute a hazard and, if so, how this hazard can be countered.

WARNING
Danger to life and limb due to smartPAD on controller that has
been switched off
If a robot controller is switched off, the EMERGENCY STOP device on
the smartPAD is not operational. There is a risk of operational and non-
operational EMERGENCY STOP devices becoming interchanged.
Death, severe injuries or damage to property may result.
• Cover smartPADs on controllers that have been switched off or re-
move them from the system.

3.6.9 External EMERGENCY STOP device

Every operator station that can initiate a robot motion or other potentially
hazardous situation must be equipped with an EMERGENCY STOP de-
vice. The system integrator is responsible for ensuring this.
There must always be at least one external EMERGENCY STOP device
installed. This ensures that an EMERGENCY STOP device is available
even when the smartPAD is disconnected.
External EMERGENCY STOP devices are connected via the customer in-
terface. External EMERGENCY STOP devices are not included in the
scope of supply of the industrial robot.

3.6.10 Enabling device

The enabling devices of the industrial robot are the enabling switches on
the smartPAD.
For robot controllers of the KR C5 series, the model smartPAD-2 is used.
It has 4 enabling switches.

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The enabling switches have 3 positions:

Safety

• Not pressed
• Center position
• Fully pressed (panic position)
In the test modes, the manipulator can only be moved if at least one of
the enabling switches is held in the center position.
It is possible to hold several enabling switches in the center position si-
multaneously. This makes it possible to adjust grip from one enabling
switch to another one.
In the test modes, the manipulator can be stopped in the following ways:
• Press at least one enabling switch down fully.
Pressing an enabling switch down fully triggers a safety stop 1.
• Or release all enabling switches.
Releasing all (!) enabling switches held in the center position triggers
a safety stop 2.

WARNING
Danger to life and limb due to lack of reaction when an enabling
switch is released
Releasing one of multiple enabling switches held in the center position
does not trigger a stop reaction.
If multiple switches are held in the center position, the robot controller
cannot distinguish whether one of them was intentionally released or if it
was unintentionally released as the result of an accident.
• Create awareness for the hazard.

If an enabling switch malfunctions (e.g. jams in the center position), the

industrial robot can be stopped using one of the following methods:

• Press another enabling switch down fully.

• Actuate the EMERGENCY STOP device.
• Release the Start key.

WARNING
Danger to life and limb due to manipulation of enabling switches
The enabling switches must not be held down by adhesive tape or other
means or tampered with in any other way. Death, severe injuries or
damage to property may result.
• Carry out a visual inspection of the enabling switches.
• Rectify tampering or remove any foreign bodies.

Function test

The function of the enabling switches must be tested in the following ca-
ses:
• Following initial start-up or recommissioning of the industrial robot
• After a software update
• After disconnecting and reconnecting a smartPAD (the same smart-
PAD or another one)
• The test must be carried out at least once every 12 months.
To test, perform the following steps separately for each enabling switch:
1. Move the manipulator in a test mode.
2. While the manipulator is moving, press the enabling switch down fully
and hold it down for 3 seconds.

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The test is passed in the following case:

Safety
• The manipulator stops.
• And: No error message for the enabling device is displayed (Enabling
switch error or similar).
If the test has not been passed for one or more enabling switches, the
smartPAD must be exchanged and the test must be performed again.

3.6.11 External enabling device

External enabling devices are required if it is necessary for more than one
person to be in the danger zone of the industrial robot.
The function of the external enabling switches must be tested at least
once every 12 months.
Which interface can be used for connecting external enabling devices is
described in the “Planning” chapter of the robot controller operating in-
structions and assembly instructions.

External enabling devices are not included in the scope of supply of the
industrial robot.

3.6.12 Velocity monitoring in T1

The axis-specific velocity is safely monitored in T1 mode.

The Cartesian velocity is safely monitored in T1 if the associated setting is
activated in the safety configuration.

Axis-specific monitoring

If an axis exceeds its velocity limit, a safety stop 0 is triggered.

• Default limit value for rotational axes: 30°/s
• Default limit value for linear axes: 250 mm/s

The axis-specific monitoring can be configured via the parameter Maxi-

mum velocity T1. Further information about this can be found in the
Operating and Programming Instructions for System Integrators
documentation for the System Software.

Cartesian monitoring

The Cartesian monitoring refers to the velocity at the flange. If a limit val-
ue is exceeded, a safety stop 0 is triggered.
• Default limit value: 250 mm/s
If an additional safety option (e.g. SafeOperation) is used, the limit value
can be configured. It can be reduced, but not increased.

3.7 Additional protective equipment

3.7.1 Jog mode

In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual

High Velocity), the robot controller can only execute programs in jog
mode. This means that it is necessary to hold down an enabling switch
and the Start key in order to execute a program.

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• Releasing the enabling switch triggers a safety stop 2.

• Pressing the enabling switch down fully (panic position) triggers a
safety stop 1.
• Releasing the Start key triggers a STOP 2.

3.7.2 Software limit switches

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
robot.
Further information is contained in the operating and programming in-
structions.

3.7.3 Mechanical end stops

Depending on the robot variant, the axis ranges of the main and wrist ax-
es of the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.
WARNING
Danger to life and limb following collision with obstacle
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator can no
longer be operated safely. Death, injuries or damage to property may re-
sult.
• Put manipulator out of operation.
• KUKA must be consulted before it is put back into operation.

3.7.4 Mechanical axis limitation (optional)

Some manipulators can be fitted with mechanical axis limitation systems

in axes A1 to A3. The axis limitation systems restrict the working range to
the required minimum. This increases personal safety and protection of
the system.
In the case of manipulators that are not designed to be fitted with me-
chanical axis limitation, the workspace must be laid out in such a way that
there is no danger to persons or material property, even in the absence of
mechanical axis limitation.
If this is not possible, the workspace must be limited by means of photo-
electric barriers, photoelectric curtains or obstacles on the system side.
There must be no shearing or crushing hazards at the loading and trans-
fer areas.
This option is not available for all robot models. Information on specific
robot models can be obtained from the manufacturer.

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3.7.5 Options for moving the manipulator without drive energy

Qualification of personnel with regard to behavior in emergency

situations
In emergencies or other exceptional situations, it may be necessary to
move the manipulator without drive energy.
• Personnel must be trained in how to move the manipulator without
drive energy.

Description

The following options are available for moving the manipulator without
drive energy after an accident or malfunction:
• Release device (optional)
The release device can be used for the main axis drive motors and,
depending 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.
• Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in
the low payload category. This is not necessary because the wrist ax-
es can be moved directly by hand.

Information about the options available for the various robot models and
about how to use them can be found in the assembly and operating in-
structions for the robot or can be requested from the manufacturer.

NOTICE
Damage to property due to moving the manipulator without drive
energy
Moving the manipulator without drive energy can damage the motor
brakes of the axes concerned.
• Only move the manipulator without drive energy in emergencies,
e.g. for rescuing persons.
• The motor must be replaced if the brake has been damaged.

3.7.6 Labeling on the industrial robot

All plates, labels, symbols and marks constitute safety-relevant parts of

the industrial 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

Further information is contained in the technical data of the operating in-

structions or assembly instructions of the components of the industrial
robot.

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3.7.7 External safeguards

The access of persons to the danger zone of the industrial robot must be
prevented 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 ISO 14120.

• 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 out-
side the enclosure.
• They do not, themselves, represent a hazard or potential hazard.
• Prescribed clearances, e.g. to danger zones, are adhered to.
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
requirements of Performance Level d and category 3 according to
EN ISO 13849-1.
• Depending on the risk situation: the safety gate is additionally safe-
guarded 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.

Further information is contained in the corresponding standards and reg-

ulations. These also include EN ISO 14120.

Other safety equipment

Other safety equipment must be integrated into the system in accordance

with the corresponding standards and regulations.

3.8 Overview of operating modes and safety functions: KSS

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
Active - - -
program verification
Jog mode Active Active - -
Software limit switches Active Active Active Active

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3.9 Overview of operating modes and safety functions: VSS

The following table indicates the operating modes in which the safety
functions are active.
Safety measures T1 T2 EXT
Operator safety active * active ** active
EMERGENCY STOP device active active active
Enabling device active active -
Reduced velocity during pro-
active - -
gram verification
Jog mode active active -
Software limit switches active active active
* In T1 mode, operator safety can be bypassed with the E2/E22 key.
** In T2 mode, operator safety can be bypassed with the E2/E22+E7 key.

3.10 Safety measures

3.10.1 General safety measures

The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons. Op-
erator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial ro-
bot even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake de-
fect) 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 possi-
ble, the manipulator and external axes must be secured by appropriate
means.
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.

DANGER
Danger to life and limb of persons under the robot arm
Sagging or falling parts can cause death or serious injuries. This applies
at all times, e.g. also for assembly tasks or with the controller switched
off.
• Never loiter under the robot arm.

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CAUTION
Risk of burns from hot motors
The motors reach temperatures during operation which can cause
burns.
• Avoid contact.
• Take appropriate safety precautions, e.g. wear protective gloves.

smartPAD

The user must ensure that the industrial robot is only operated with the
smartPAD by authorized persons.
If more than one smartPAD is used in the overall system, it must be en-
sured that it is clearly recognizable which smartPAD is connected to which
industrial robot. They must not be interchanged.
WARNING
Danger to life and limb due to disconnected smartPAD
If a smartPAD is disconnected, its EMERGENCY STOP device is not
operational. There is a risk of connected and disconnected smartPADs
being interchanged. Death, injuries or damage to property may result.
• Remove the disconnected smartPAD from the system immediately.
• Store the disconnected smartPAD out of sight and reach of person-
nel working on the industrial robot.

The enabling switches on the smartPAD must be subjected to a function

test at least once every 12 months and in certain specific cases.
(>>> "Function test" Page 30)

Modifications

After modifications to the industrial robot, 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.
New or modified programs must always be tested first in Manual Reduced
Velocity 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
components of the industrial robot and includes e.g. modifications of the
external axes or to the software and configuration settings.

Faults

The following tasks must be carried out in the case of faults in the indus-
trial robot:
• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
• Eliminate the fault and carry out a function test.

3.10.2 IT security

KUKA products must only be used in perfect technical condition in accord-

ance with their intended use and only by safety-conscious persons.

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In particular, safety-conscious use includes being operated in an IT envi-

Safety
ronment which meets the current security-relevant standards and for
which there is an overall concept for IT security.
Take measures to ensure IT security
IT security involves not only aspects of information and data processing
as such, but also affects at least the following areas:
• Technology, organization, personnel, infrastructure
KUKA urgently recommends that users implement an information securi-
ty management system for their products which designs, coordinates
and monitors the tasks related to information security.

Sources for information about IT security for companies include:

• Independent consulting firms
• National cyber security authorities
National authorities often make their recommendations available on the In-
ternet. In addition to their official language, some national authorities pro-
vide their information in English.

3.10.3 Transportation

Manipulator

The prescribed transport position of the manipulator must be observed.

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot.
Avoid vibrations and impacts during transportation in order to prevent
damage to the manipulator.

Robot controller

The prescribed transport position of the robot controller must be observed.

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot controller.
Avoid vibrations and impacts during transportation in order to prevent
damage to the robot controller.

External axis (optional)

The prescribed transport position of the external axis (e.g. KUKA linear
unit, turn-tilt table, positioner) must be observed. Transportation must be
carried out in accordance with the operating instructions or assembly in-
structions of the external axis.

3.10.4 Start-up and recommissioning: KSS/VSS

KSS only:
Changing default passwords
The KUKA System Software is supplied with default passwords for the
user groups. If the passwords are not changed, this enables unauthor-
ized persons to log on.
• Before start-up, change the passwords for the user groups.
• Only communicate the passwords to authorized personnel.

KSS and VSS:

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Before starting up systems and devices for the first time, a check must be
Safety

carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
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.
WARNING
Danger to life and limb due to incorrectly assigned cables
The robot controller is preconfigured for the specific industrial robot. The
manipulator and other components can receive incorrect data if they are
connected to a different robot controller. Death, severe injuries or dam-
age to property may result.
• Only connect the manipulator to the corresponding robot controller.

WARNING
Risk of fatal injury due to non-configured external axes
The robot controller cannot detect an external axis that is physically
connected, but not configured correctly in the software. It cannot exert
any torque nor any holding torque on this external axis. If the brakes re-
lease, uncontrolled motion can occur at this external axis as a result.
Death, severe injuries or damage to property may result.
• Ensure that external axes are correctly configured before an ena-
bling switch is pressed and the brakes are thus released.

Do not impair safety functions

Additional components (e.g. cables and hoses) not supplied by KUKA
may be integrated into the industrial robot. If the safety functions are not
taken into consideration, this may result in death, severe injuries or
damage to property.
• Additional components must not impair or disable safety functions.

NOTICE
Damage to property due to condensation
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form. This may result
in damage to property.
• Wait until the internal cabinet temperature has adapted to the ambi-
ent temperature in order to avoid condensation.

Function test

The following tests must be carried out before start-up and recommission-
ing:
General test:
It must be ensured that:

• The industrial robot is correctly installed and fastened in accordance

with the specifications in the documentation.
• There is no damage to the robot that could be attributed to external
forces.

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Safety
WARNING
Danger to life and limb resulting from external forces
External forces, such as an impact or a collision, can cause non-
visible damage. For example, it can lead to a gradual loss of drive
power from the motor, resulting in unintended movements of the ma-
nipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
‒ In the case of damage, the affected components must be ex-
changed.

• There are no foreign bodies or defective or loose parts on the industri-

al 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 suffi-
ciently 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 en-
sure that they are functioning correctly:

• Local EMERGENCY STOP device

• External EMERGENCY STOP device (input and output)
• Enabling device (in the test modes)
• Operator safety
• All other safety-relevant inputs and outputs used
• Other external safety functions

3.10.4.1 Checking machine data and safety configuration

WARNING
Danger to life and limb due to incorrect data
The industrial robot must not be moved if incorrect machine data or an
incorrect controller configuration are loaded. Unforeseeable reactions
may occur. Death, severe injuries or damage to property may result.
• Only operate industrial robots with correct data.

• Following the start-up procedure, the practical tests for the machine
data must be carried out. The tool must be calibrated (either via an
actual calibration or through numerical entry of the data).
• Following modifications to the machine data, the safety configuration
must be checked.
• After activation of a WorkVisual project on the robot controller, the
safety configuration must be checked.

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• If machine data are adopted when checking the safety configuration

(regardless of the reason for the safety configuration check), the prac-
tical tests for the machine data must be carried out.
• If the activation code of the safety configuration has changed, the safe
axis monitoring functions must be checked.

Information about checking the safety configuration and the safe axis
monitoring functions is contained in the Operating and Programming In-
structions for System Integrators.

If the practical tests are not successfully completed in the initial start-up,
KUKA Deutschland GmbH must be contacted.
If the practical tests are not successfully completed during a different pro-
cedure, the machine data and the safety-relevant controller configuration
must be checked and corrected.

General practical test

If practical tests are required for the machine data, this test must always
be carried out.
For 6-axis robots:
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 calibra-
ted.
Or:
1. Align the TCP with a freely selected point. The point serves as a ref-
erence point.
• The point must be located so that reorientation is possible.
• The point must not be located on the Z axis of the FLANGE coor-
dinate system.
2. Move the TCP manually at least 45° once in each of the A, B and C
directions.
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 mov-
ing in the next direction.
The practical test is passed if the TCP does not deviate from the ref-
erence point by more than 2 cm in total.
For palletizing robots:
Palletizing robots, in this case, are either robots that can be used only as
palletizers from the start or robots operated in palletizing mode. The latter
must also be in palletizing mode during the practical test.
First part:
1. Mark the starting position of the TCP.
Also read and note the starting position from the Actual position –
Cartesian display on the smartHMI.
2. Jog the TCP in the X direction. The distance must be at least 20% of
the robot’s maximum reach. Determine the exact length via the Actual
position display.
3. Measure the distance covered and compare it with the distance value
displayed on the smartHMI. The deviation must be < 5%.
4. Repeat steps 1 and 2 for the Y direction and Z direction.
The first part of the practical test is passed if the deviation is < 5% in ev-
ery direction.

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Second part:

Safety
• Rotate the tool manually about A by 45°: once in the plus direction,
once in the minus direction. At the same time, observe the TCP.
The second part of the practical test is passed if the position of the TCP
in space is not altered during the rotations.

Practical test for axes that are not mathematically coupled

If practical tests are required for the machine data, this test must be car-
ried out when axes are present that are not mathematically coupled.
1. Mark the starting position of the axis that is not mathematically cou-
pled.
Also read and note the start position from the Actual position display
on the smartHMI.
2. Move the axis manually by a freely selected path length. Determine
the path length from the Actual position display.
• 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
displayed on the smartHMI.
The practical test is passed if the values differ by no more than 5%.
4. Repeat the test for each axis that is not mathematically coupled.

Practical test for robot on ROBROOT kinematic system

If practical tests are required for the machine data, this test must be car-
ried out if the robot is mounted on a mathematically coupled ROBROOT
kinematic system, e.g. on a KL.
• Move the axes of the ROBROOT kinematic system manually in Carte-
sian mode, individually and one after the other.
The practical test is passed if the TCP does not move at the same
time.

Practical test for couplable axes

If practical tests are required for the machine data, this test must be car-
ried out when axes are present that can be physically coupled and uncou-
pled, 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 re-
maining axes.

3.10.4.2 Start-up mode

Description

The industrial robot can be set to Start-up mode via the smartHMI user in-
terface. In this mode, the manipulator can be moved in T1 without the ex-
ternal safeguards being put into operation.
The safety interface used affects “Start-up” mode:
• Discrete safety interface
Start-up mode is always possible.

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• Ethernet safety interface

The robot controller prevents or terminates Start-up mode if a connec-
tion 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
configuration specifies for this to switch in accordance with the motion en-
able, then the same also applies in Start-up mode. This means that if mo-
tion enable is present, the US2 voltage is switched on – even in Start-up
mode.
The maximum number of switching cycles of the peripheral contactors is
175 per day.

Hazards

Possible hazards and risks involved in using Start-up mode:

• A person walks into the manipulator’s danger zone.

• In a hazardous situation, a disabled external EMERGENCY STOP de-
vice is actuated and the manipulator is not shut down.
Additional measures for avoiding risks in Start-up mode:

• Cover disabled EMERGENCY STOP devices or attach a warning sign

indicating that the EMERGENCY STOP device is out of operation.
• If there is no safety fence, other measures must be taken to prevent
persons from entering the manipulator’s danger zone, e.g. use of
warning tape.

Use

Intended use of Start-up mode:

• Start-up in T1 mode when the external safeguards have not yet been
installed or put into operation. The danger zone must be delimited at
least by means of warning tape.
• Fault localization (periphery fault).
• Use of Start-up mode must be minimized as much as possible.

WARNING
Risk of fatal injury due to non-operational external safeguards
Use of Start-up mode disables all external safeguards. Death, severe in-
juries or damage to property may result.
• There must be no persons in the danger zone of the manipulator
while it is in Start-up mode.

Misuse

Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. It will result in the loss of warranty and liability
claims. KUKA is not liable for any damage resulting from such misuse.

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Safety
3.10.5 Manual mode

General

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 opera-
tion. 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 Re-
duced 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
result 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
safeguarded area.

Setup work in T1

If it is necessary to carry out setup work from inside the safeguarded

area, the following must be taken into consideration in the operating mode
Manual Reduced Velocity (T1):
• If it can be avoided, there must be no other persons inside the safe-
guarded area.
• If it is necessary for there to be several persons inside the safeguar-
ded area, the following must be observed:
‒ Each person must have an enabling device.
‒ All persons must have an unimpeded view of the industrial robot.
‒ Eye-contact between all persons must be possible at all times.
• The operator must be so positioned that he can see into the danger
area and get out of harm’s way.
• Unexpected motions of the manipulator cannot be ruled out, e.g. in
the event of a fault. For this reason, an appropriate clearance must be
maintained between persons and the manipulator (including tool).
Guide value: 50 cm.
The minimum clearance may vary depending on local circumstances,
the motion program and other factors. The minimum clearance that is
to apply for the specific application must be decided by the user on
the basis of a risk assessment.

Setup work in T2

If it is necessary to carry out setup work from inside the safeguarded

area, the following must be taken into consideration in the operating mode
Manual High Velocity (T2):
• This mode may only be used if the application requires a test at a ve-
locity higher than that possible in T1 mode.
• Teaching and programming are not permissible in this operating mode.
• Before commencing the test, the operator must ensure that the ena-
bling devices are operational.

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• The operator must be positioned outside the danger zone.

• There must be no other persons inside the safeguarded area. It is the
responsibility of the operator to ensure this.

3.10.6 Simulation

Simulation programs do not correspond exactly to reality. Robot programs

created in simulation programs must be tested in the system in Manual
Reduced Velocity mode (T1). It may be necessary to modify the pro-
gram.

3.10.7 Automatic mode

Automatic mode is only permissible in compliance with the following safety

measures:

• All safety equipment and safeguards are present and operational.

• There are no persons in the system.
• The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for
no apparent reason, the danger zone must not be entered until an EMER-
GENCY STOP has been triggered.

3.10.8 Maintenance and repair

After maintenance and repair work, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regula-
tions 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
operational state. Repair work includes troubleshooting in addition to the
actual repair itself.
The following safety measures must be carried out when working on the
industrial 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 addi-
tional safety measures 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.
• The EMERGENCY STOP devices must remain active. If safety func-
tions or safeguards are deactivated during maintenance or repair work,
they must be reactivated immediately after the work is completed.

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Safety
DANGER
Danger to life and limb due to live parts
The robot system must be disconnected from the mains power supply
prior to work on live parts. It is not sufficient to trigger an EMERGENCY
STOP or safety stop, because parts remain live. Death or severe inju-
ries may result.
• Before commencing work on live parts, turn off the main switch and
secure it against being switched on again.
If the controller variant in question does not have a main switch
(e.g. KR C5 micro), turn off the device switch then disconnect the
power cable and secure it so it cannot be reconnected.
• Then check to ensure that the system is deenergized.
• Inform the individuals involved that the robot controller is switched
off. (e.g. by affixing a warning sign)

Faulty components must be replaced using new components with the

same article numbers or equivalent components approved by KUKA
Deutschland GmbH for this purpose.
Cleaning and preventive maintenance work is to be carried out in accord-
ance with the operating instructions.

Robot controller

Even when the robot controller is switched off, parts connected to periph-
eral devices may still carry voltage. The external power sources must
therefore be switched off if work is to be carried out on the robot control-
ler.
The ESD regulations must be adhered to when working on components in
the robot controller.
Voltages in excess of 50 V (up to 780 V) can be present in various com-
ponents for several minutes after the robot controller has been switched
off! To prevent life-threatening injuries, no work may be carried out on the
industrial robot in this time.
On robot controllers with transformers, the transformers must be discon-
nected before working on components in the robot controller.
Water and dust must be prevented from entering the robot controller.

Counterbalancing system

Some robot variants are equipped with a hydropneumatic, spring or gas

cylinder counterbalancing system.
• Counterbalancing system classified below category I: is subject to
the Pressure Equipment Directive but exempt from application of the
Pressure Equipment Directive according to Art. 4, para. 3 and there-
fore not CE marked.
• Counterbalancing system classified as category I or higher: is
subject to the Pressure Equipment Directive and CE marked as a
component (see rating plate of the counterbalancing system). The
pressure equipment is placed on the market in conjunction with partly
completed machinery. Conformity is expressed on the declaration of
incorporation according to the Machinery Directive.
The user must comply with the applicable national laws, regulations and
standards pertaining to pressure equipment.
• In Germany, the counterbalancing system is work equipment according
to the German Ordinance on Industrial Safety and Health (BetrSichV).
Inspection intervals in Germany in accordance with the Ordinance on

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Industrial Safety and Health, Sections 14 and 15. Inspection by the

Safety

user before commissioning at the installation site.

• Inspection intervals in all other countries must be researched and ob-
served. As a rule, however, at least the maintenance intervals speci-
fied by KUKA must be observed. Shorter intervals are not permitted.
The following safety measures must be carried out when working on the
counterbalancing system:
• The assemblies supported by the counterbalancing systems must be
secured.
• Work on the counterbalancing systems must only be carried out by
qualified personnel.

Hazardous substances

The following safety measures must be carried out when handling hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.
• Clean skin and apply skin cream.

Use current safety data sheets

Knowledge of the safety data sheets of the substances and mixtures
used is a prerequisite for the safe use of KUKA products. Death,
injuries or damage to property may otherwise result.
• Request up-to-date safety data sheets from the manufacturers of
hazardous substances regularly.

3.10.9 Decommissioning, storage and disposal

The industrial robot must be decommissioned, stored and disposed of in

accordance with the applicable national laws, regulations and standards.

3.10.10 Safety measures for single point of control

Overview

If certain components are used on the industrial robot, safety measures

must be taken to ensure complete implementation of the principle of “sin-
gle 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
• KUKA.DeviceConnector
(not KUKA.DeviceConnector pre-installed)
Since only the system integrator knows the safe states of actuators in the
periphery 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.

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Safety
Further safety measures for Single Point of Control
Depending on the specific application, further safety measures may be
required to ensure complete implementation of the principle of “single
point of control”. Failure to take this precaution into consideration may
result in death, injuries or damage to property.
• Check whether further safety measures are required; if so, imple-
ment them.

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 interpreter, PLC

If motions, (e.g. drives or grippers) are controlled with the submit interpret-
er or the PLC via the I/O system, and if they are not safeguarded by oth-
er means, then this control will take effect even in T1 and T2 modes or
while an EMERGENCY 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.
• In T1 and T2, the system variable $OV_PRO must not be written to
by the submit interpreter or the PLC.

OPC server, KUKA.DeviceConnector, remote control tools

These components can be used with write access to modify programs,

outputs or other parameters of the robot controller, without this being no-
ticed by any persons located inside the system.
Safety measure:
If these components are used, outputs that could cause a hazard must be
determined 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 external enabling device, for example.

Tools for configuration of bus systems

If these components have an online functionality, they can be used with

write access to modify programs, outputs or other parameters of the robot
controller, 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
controller must not be modified using these components.

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Technical data
4 Technical data

4.1 Basic data

KR C5 micro
Maximum number of servo axes 6
Weight approx. 9.8 kg
Protection rating (IEC 60529) IP20
Sound level < 60 dB (A)
Default color Housing: iron gray (RAL 7011);
Housing base: light gray (RAL
7035)
Load on cabinet roof 250 N with even distribution
Clearance for side-by-side installa- -
tion
Condensation must not occur during operation.
Rated supply voltage AC 1x 200 V - 240 V
Rated supply voltage tolerance ± 10 %
Rated connected load 1.30 kVA
System impedance ≤ 300 mΩ
Ground leakage current ≤ 10 mA
Mains-side fusing 1x 16 A slow-blowing, type C
Mains frequency 50...60 Hz
Thermal output max. 250 W
Alternative power supply connection: two-phase with grounded neutral (as
symmetrical as possible) between the phases used (>>> 5.8 "Power sup-
ply connection" Page 67)
Humidity class (EN 60204) -
Classification of environmental 3K4
conditions (EN 60721-3-3)
Temperature change 1.1 K/min
Ambient temperature
During operation 0 °C to 45 °C (273 K to 318 K)
During storage/transportation -25 °C to 70 °C (248 K to 343 K)
During operation with cooling unit -
During storage/transportation with- -
out battery
Altitude
Without derating max. 2000 m above mean sea lev-
el
With derating max. 3000 m above mean sea lev-
el (derating 5%/1000 m)

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Technical data KR C5 micro

Overvoltage category II From 2000 m to 3000 m above

mean sea level
Overvoltage category III up to 2000 m above mean sea
level
Degree of fouling 2

Vibration resistance

r.m.s. acceleration (sustained oscillation)

During operation 3 g
During transportation 3 g
Frequency range (sustained oscillation)
During operation 10...2000 Hz
During transportation 10...2000 Hz
Acceleration (shock in X/Y/Z direction)
During operation 10 g
During transportation 10 g
Waveform/duration (shock in X/Y/Z direction)
During operation Half-sine/11 ms
During transportation Half-sine/11 ms
If more severe mechanical stress is expected, the controller must be in-
stalled on anti-vibration components.

Safe outputs

Each safe output of type “Relay” is rated for a maximum number of

switching cycles during its service life.
Switching cycles Service life: 20 years
< 1,900,000 (corresponds to 260
switching cycles per day)
The module must be exchanged when the number of switching cycles is
exceeded.

Safe inputs

Switching level of the inputs The state for the inputs is not de-
fined for the voltage range from
5 V to 11 V (transition range). Ei-
ther the ON state or the OFF state
is set.

• Signal Off / 0:
OFF state for the voltage
range from -3 V to 5 V (OFF
range).
• Signal On / 1:
ON state for the voltage range
from 11 V to 30 V (ON range).
Capacitive load for the inputs per < 200 nF
channel and connected switching
device

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Technical data
Resistive load for the inputs per < 33 Ω
channel and connected switching
device

4.2 Dimensions

The dimensions of the robot controller are indicated in the following dia-
gram.

Fig. 4-1: Dimensions

4.3 Minimum clearances, robot controller

The minimum clearances that must be maintained for the robot controller
are indicated in the diagram (>>> Fig. 4-2).

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Fig. 4-2: Minimum clearances

NOTICE
Damage to property due to failure to maintain minimum clearances
If the minimum clearances are not maintained, this can result in damage
to the robot controller.
• Always maintain the specified minimum clearances.

NOTICE
Damage to property due to build-up of discharged heat
If the heat discharged by the robot controller is not dissipated, this may
lead to unintentional shutdowns or a shortened service life of the robot
controller.
• Position the robot controller in such a way that the discharged heat
cannot accumulate.

Certain maintenance and repair tasks on the robot controller

(>>> 9 "Maintenance" Page 107) (>>> 10 "Repair" Page 111) must be
carried out from the side or from the rear. The robot controller must be
accessible for this. If the side or rear panels are not accessible, it must
be possible to move the robot controller into a position in which the
work can be carried out.

4.4 Minimum clearances for installation in an external housing

When installing the robot controller in a closed external housing, it must

be ensured that the thermal output of the robot controller is dissipated.
Requirements for installation of the KR C5 micro in an external housing:
• Distance between front of robot controller (air inlet) and housing: min.
150 mm
• Distance between rear of robot controller (air outlet) and housing: min.
100 mm

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Technical data
4.5 Plates and labels

Overview

The following plates and labels are attached to the robot controller. They
must not be removed or rendered illegible. Illegible plates and labels must
be replaced.

Fig. 4-3: Plates and labels on front

Item Description
1

KSP identification plate

2, 4

General warning
Warning of potential hazard

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Item Description
3

Protective equipotential bonding connection

Fig. 4-4: Plates and labels on rear

Item Description
3

Robot controller rating plate

Contains the article number and serial number of the robot con-
troller
1

Electric shock hazard

The labeled cover of the power unit must not be opened.

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Item Description
2

Protective equipotential bonding connection

The plates may vary slightly from the examples illustrated above de-
pending on the specific cabinet type or as a result of updates.

4.6 REACH duty to communicate information acc. to Art. 33

As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment and of the Council dated 18 December 2006 on the registration,
evaluation and authorization of chemicals (REACH Regulation) is in force.
Detailed REACH information can be found in the product information in
KUKA Xpert.

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5 Planning

5.1 Overview of planning

This is an overview of the most important planning specifications. The

precise planning depends on the application, the manipulator type, the
technology packages used and other customer-specific circumstances.
For this reason, the overview does not claim to be comprehensive.

Robot controller

Step Description Information

1 Electromagnetic compatibility (>>> 5.2 "Electromagnetic
(EMC) compatibility (EMC)"
Page 57)
2 Installation conditions for ro- (>>> 5.3 "Installation condi-
bot controller tions" Page 58)
3 Connection conditions (>>> 5.6 "Connection condi-
tions" Page 65)
4 PE equipotential bonding (>>> 5.5 "PE equipotential
bonding" Page 64)
5 Power supply connection (>>> 5.8 "Power supply con-
nection" Page 67)
6 Safety interfaces XG11.1 (>>> 5.9.8.2 "Safety inter-
and XG58 face XG11.1" Page 81)
(>>> 5.9.8.1 "Interface
XG58, external enabling
switch" Page 79)
7 Ethernet interface (>>> 5.9.3.1 "KSI interface"
Page 72)
(>>> 5.9.3.4 "KLI interfaces"
Page 73)
(>>> 5.9.3.5 "KLI IT inter-
face" Page 73)

8 EtherCAT interface
(>>> 5.9.3.6 "KEI interface"
Page 73)
9 Optional interfaces (>>> 5.9.3.3 "Daisy chain in-
terface" Page 73)
10 Performance level (>>> 5.10 "Performance lev-
el" Page 93)

5.2 Electromagnetic compatibility (EMC)

Description

If connecting cables (e.g. field buses, etc.) are routed to the system board
from outside, only shielded cables with an adequate degree of shielding
may be used.

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The robot controller corresponds to EMC class A, Group 1, in accord-

ance with EN 55011 and is intended for use in an industrial setting. In
the case of use in other environments, additional measures must be tak-
en to ensure electromagnetic compatibility.

5.3 Installation conditions

The dimensions and installation conditions of the robot controller are

specified in the chapter “Technical data”.
(>>> 4.1 "Basic data" Page 49)
(>>> 4.2 "Dimensions" Page 51)
(>>> 4.3 "Minimum clearances, robot controller" Page 51)
NOTICE
In addition to observing the installation conditions, it must be ensured
that all plug connections on the robot controller are easily accessible.

The robot controller can be installed as a standalone device, stacked, or

on the wall, or mounted on a mounting plate as a panel-mount variant for
further installation. The robot controller can optionally be installed in a 19"
rack. The specifications in the chapter “Technical data” (>>> 4.1 "Basic da-
ta" Page 49) must be observed.
The robot controller is designed for use in the horizontal position. The ro-
bot controller can optionally be operated in the vertical position.
CAUTION
Risk of injury and damage to property due to conductive dirt or
condensation
If the robot controller is operated in an environment with conductive dirt
or condensation, this can lead to uncontrolled electrical connections in-
side the robot controller. Injuries or damage to property may result.
• The robot controller may only be operated in environments without
conductive dirt.
• Avoid humidity and condensation.

CAUTION
Risk of injury and damage to property due to operation in non-ap-
proved environment
If the robot controller is operated in an environment with a higher de-
gree of fouling and possibly with formation of condensation, this can
lead to uncontrolled electrical connections inside the robot controller.
These ambient conditions correspond to degree of fouling 3 or 4.
Non-compliance can result in injury or damage to property.
• In the case of environments with heavy fouling, the robot controller
must be integrated into an appropriate protective enclosure.
• It must be ensured that the installation site is protected from con-
ductive fouling or condensation, e.g. through an appropriate housing
or cabinet with a protective rating of at least IP 54. The required
protective rating for the housing or cabinet must always be deter-
mined on the basis of the given ambient conditions and may be
higher than IP 54.

Installing the robot controller

The robot controller can be installed with or without holders on an even

surface or integrated into a cabinet.

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Fig. 5-1: Operation without holders

The front and rear sides of the robot controller must always be accessible
to the cooling air.

Mounting brackets 19" frame

If the robot controller is to be installed in a 19" rack, a Mounting brackets

19" frame must be used. The depth of the 19" insert must be at least
700 mm.

Fig. 5-2: Mounting brackets 19" frame

The Mounting brackets 19" frame must be installed in a 19" rack before
inserting the robot controller. (>>> 10.2 "Exchanging the Mounting brack-
ets 19" frame" Page 112)

Robot controller stacked

One robot controller can be stacked on top of another one. The holders of
the robot controller must be used for this purpose. The lower robot con-
troller should be fastened to the floor.
To fasten the upper controller, the 4 holders must be mounted diagonally
on the upper and lower controller as illustrated in (>>> Fig. 5-3).

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Fig. 5-3: Stacked robot controller (flat)

NOTICE
A maximum of 3 robot controllers can be stacked one on top of the oth-
er.

Standing on side

The robot controller can be installed standing on its side on an even sur-
face or integrated into a cabinet. The holders of the robot controller must
be used for this purpose.

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Fig. 5-4: Robot controller standing on side

Installation on wall

If the robot controller is installed on the wall or mounted on a mounting

plate as a panel-mount variant, it must be taken into consideration that
the air inlet for cooling is on the underside.
Two installation positions are possible:
• Flat installation on wall (>>> Fig. 5-5)
• Vertical installation on wall (>>> Fig. 5-6)
The holders of the robot controller must be used for installation on the
wall or on a mounting plate as a panel-mount variant.

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Fig. 5-5: Flat installation on wall

Fig. 5-6: Vertical installation on wall

5.4 Installation with holders

If the robot controller is fastened with the holders to an even surface, wall
or mounting plate, the dimensions of the drilling templates must be ob-
served.
Screws required:
• Horizontal installation: M5
• Vertical installation: M6

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Fig. 5-7: Installation with holders (1)

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Fig. 5-8: Installation with holders (2)

5.5 PE equipotential bonding

Description

The following cables must be connected before start-up:

• A 4 mm2 cable as protective equipotential bonding between the ma-
nipulator and the robot controller.
• An additional PE conductor between the central PE rail of the supply
cabinet and the PE connection of the robot controller. A cross-section
of 4 mm2 is recommended.
The following connection options are available on the front or rear side of
the robot controller for the two PE connections:

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Fig. 5-9: Equipotential bonding between the manipulator and the robot controller

1 Equipotential bonding connection on the front of the robot controller

2 Protective equipotential bonding between the manipulator and the
robot controller
3 PE cable to the central PE rail of the supply cabinet
4 Equipotential bonding connections on the rear of the robot control-
ler

5.6 Connection conditions

The robot controller may only be connected to grounded-neutral power

supply systems.
Rated supply voltage AC 1x 200 V - 240 V
Rated supply voltage tolerance ± 10 %
Rated connected load 1.30 kVA
System impedance ≤ 300 mΩ
Ground leakage current ≤ 10 mA
Mains-side fusing 1x 16 A slow-blowing, type C
Mains frequency 50...60 Hz
Thermal output max. 250 W

CAUTION
If the robot controller is connected to a power system without a groun-
ded neutral, this may cause malfunctions in the robot controller and ma-
terial damage to the power supply units. Electrical voltage can cause in-
juries. The robot controller may only be operated with grounded-neutral
power supply systems.

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If use of a residual-current circuit-breaker (RCCB) is planned, we rec-

ommend the following RCCB: trip current difference 30 mA type B, uni-
versal-current sensitive, selective.

5.7 Routing the connecting cables

Overview

• A connecting cable set is supplied with the industrial robot. In the

standard version this consists of:
‒ Motor cables to the manipulator
‒ Data cables to the manipulator

• The following cables may be provided for additional applications:

‒ Peripheral cables

Bending radius

The following bending radii must be observed:

• Fixed installation: 3 ... 5 x cable diameter.
• Installation in cable carrier: 7 ... 10 x cable diameter (cable must be
specified for this).

WARNING
Danger to life and limb due to incorrectly assigned cables
The robot controller is preconfigured for the specific industrial robot. The
manipulator and other components can receive incorrect data if they are
connected to a different robot controller. Death, severe injuries or dam-
age to property may result.
• Only connect the manipulator to the corresponding robot controller.

NOTICE
Route the connecting cables between the robot and the robot controller
in such a way as to exclude the possibility of damage to the cables.

NOTICE
Route the motor cables to the manipulator junction box separately from
the data cables.

Fig. 5-10: Example: Installing the cables in the cable duct

1 Cable duct 4 Motor cables

2 Separating web 5 Data cables
3 Welding cables

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CAUTION
Risk of injury and damage to property due to incorrect mastering
after exchange of the data cable
Following a defect with subsequent exchange of the data cable, the
mastering may be incorrect. Injuries or damage to property may result.
• Following an exchange of the data cable, carry out mastering or per-
form a mastering test of all axes.

5.8 Power supply connection

Description

For connection to the mains, the robot controller is equipped with a 3-pole
high-temperature appliance inlet of type C15. The robot controller must be
connected to the mains via the device connection cable included in the
scope of supply or the mains connector included in the scope of supply.

Connector pin allocation XD1

Pin Description
1 L1
2 N
PE PE

Infeed

• Single-phase:
‒ AC 200-240 V ± 10%, single-phase TN system
‒ AC 200-240 V ± 10%, single-phase 3-wire system (single/split
phase)
‒ 50 Hz ± 1 Hz or 60 Hz ± 1 Hz
• Two-phase:
‒ 208 Y / 120 V ±10% solidly grounded wye, 3-phase, 4-wire
‒ 240 Y / 131 V ±10% solidly grounded wye, 3-phase, 4-wire
‒ 50 Hz ± 1 Hz or 60 Hz ± 1 Hz
In the systems specified above with grounded neutral, the controller must
be connected to 2 phases so that there is a supply voltage present in the
range 200 … 240 V ±10%.

Device-side fusing

• 2x 10 A slow-blowing, type C

5.9 Overview of interfaces

The robot controller has the following interfaces that are connected to the
specified boards:

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Board Interfaces
FCU-300 • XD1
• XD2
• XD20.1
• XD20.2
SCU-6-1S • XG11.1
• XF21
• XG33
• XG58
“Basic” system board • XGSD
• XFUSB 1, XFUSB 2
• XF1 - XF6
• XGDP
• XG19
“Performance” system board • XGSD
• XFUSB 1, XFUSB 2
• XF1 - XF8
• XGDP
• XG19
“Standard” interface board • XD12, XD12.1
• XG12
The following interfaces are available on the front and rear of the robot
controller:

Front view with “Basic” system board

Fig. 5-11: Connection panel, front view

1 XGSD interface for SD card

2 USB 3.0 interfaces XFUSB1 and XFUSB2

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3 Ethernet and EtherCAT interfaces for “Basic” system board:

• XF1 KSI interface (KUKA Service Interface)

• XF2 KEI interface (KUKA EtherCAT Interface)
• XF3 KUKA internal daisy chain “Next Robot”
• XF4 KUKA internal daisy chain “Pre Robot”
• XF5 KLI 2 interface (KUKA Line Interface)
• XF6 KLI 1 interface (KUKA Line Interface)
4 XGDP interface
Display port DP 1.2
5 XG19 interface for smartPAD connection
6 24 V supply for external customer interface XG12

• XD12 interface 24 V PWR IN

• XD12.1 interface 24 V PWR OUT
7 XG12 interface for connection of 16 digital inputs/outputs (I/O)
8 XD20.1 motor interface 1 for connection of axes A1-A3
9 XG33 (3 Fast Measurement inputs and 1 UL lamp output)
10 XF21 interface RDC
11 XG58 safety interface (2 safe inputs for external enabling device
and additional EMERGENCY STOP)
12 XG11.1 safety interface (2 safe inputs, 1 safe output)
13 XD20.2 motor interface 2 for connection of axes A4-A6

Front view with “Performance” system board

Fig. 5-12: Connection panel, front view

1 XGSD interface for SD card

2 USB 3.0 interfaces XFUSB1 and XFUSB2

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3 Ethernet and EtherCAT interfaces for “Performance” system board:

• XF1 KSI interface (KUKA Service Interface)

• XF2 KLI IT interface (KUKA Line Interface IT)
• XF3 KUKA internal daisy chain “Next Robot”
• XF4 KUKA internal daisy chain “Pre Robot”
• XF5 KLI 2 interface (KUKA Line Interface)
• XF6 KLI 1 interface (KUKA Line Interface)
• XF7 KONI interface
• XF8 KEI interface (KUKA EtherCAT Interface)
4 XGDP interface
Display port DP 1.2
5 XG19 interface for smartPAD connection
6 24 V supply for external customer interface XG12

• XD12 interface 24 V PWR IN

• XD12.1 interface 24 V PWR OUT
7 XG12 interface for connection of 16 digital inputs/outputs (I/O)
8 XD20.1 motor interface 1 for connection of axes A1-A3
9 XG33 (3 Fast Measurement inputs and 1 UL lamp output)
10 XF21 interface RDC
11 XG58 safety interface (2 safe inputs for external enabling device
and additional EMERGENCY STOP)
12 XG11.1 safety interface (2 safe inputs, 1 safe output)
13 XD20.2 motor interface 2 for connection of axes A4-A6

Rear view

Fig. 5-13: Connection panel, rear view

1 Device switch
2 Fuses F1 and F2
3 XD1 interface, power supply connection
4 XD2 interface

• 24 V power supply of the UPS

• Daisy chain connection to other robot controllers

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5.9.1 XGSD interface, SD card

Description

Project data can be saved using the XGSD interface and the SD card.

5.9.2 USB interface

Only USB sticks, keyboard, mouse and passive hubs (without their own
power supply) may be connected to the XFUSB interfaces.

The maximum permissible cable length of the connected interface is

5 m.

5.9.3 Interfaces XF1 - XF8

Description

Interfaces XF1 to XF8 are Ethernet and EtherCAT interfaces to the “Basic”
system board (XF1 - 6) or “Performance” system board (XF1 - 8).
System board
Interface “Basic” “Performance”
KSI XF1 XF1 • 10Base-T Auto-Negotiation
KONI - XF7 • 100Base-TX Auto-Negotiation
KUKA internal daisy XF3 XF3 • 1000Base-T Auto-Negotiation
chain OUT
KUKA internal daisy XF4 XF4
chain IN
KLI 2 XF5 XF5
KLI 1 XF6 XF6
KLI IT XF2
KEI XF2 XF8 • 100Base-TX Auto-Negotiation

Necessary equipment

• Connector RJ45
• Recommended connecting cable: Ethernet-compatible, min. category
CAT 5e

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Pin assignment

Fig. 5-14: Pin assignment

Connector pin allocation

Pin assignment for the interfaces “Basic” system board (XF1 - 6) and
“Performance” system board (XF1 - 8).
Pin Description
1 BI_DB+
2 BI_DB-
3 BI_DA+
4 BI_DD+ Not assigned for KEI interface.
5 BI_DD-
6 BI_DA-
7 BI_DC+ Not assigned for KEI interface.
8 BI_DC-

5.9.3.1 KSI interface

Description

The KSI interface is intended for connecting a notebook for the purpose of
diagnosis, WorkVisual configuration, update, etc., via the KSI (KUKA Serv-
ice Interface).
The KSI interface must not be connected to an IT network (e.g. to DHCP
servers).
The connected device must be certified in accordance with EN 60950-1.

The maximum permissible cable length of the connected interface is

100 m.

5.9.3.2 KONI interface

Description

The KONI interface can be used for internal and external communication.
The KONI interface is primarily intended as an interface for KUKA technol-
ogy packages. This involves implementing specific applications of the KU-

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KA technology packages (e.g. connecting a camera). The interface is acti-

Planning
vated via the software (default: not active).

5.9.3.3 Daisy chain interface

Description

Multiple robot controllers can be connected in series by means of daisy

chaining using a bus system via the two interfaces XF3 and XF4. The re-
sulting network can be used, for example, for implementing RoboTeam
functionalities:
• XF3 connection to the next robot controller (daisy chain interface OUT)
• XF4 connection to the previous robot controller (daisy chain interface
IN)

5.9.3.4 KLI interfaces

Description

The KLI interfaces are equivalent. The interfaces can be used to connect
OT networks or IT networks. The following connections are possible:
• KLI 1: Interface to the PLC (e.g. Profinet with ProfiSafe or EtherNet/IP
with CIP Safety)
• KLI 2: Interface to the terminal (e.g. Profinet or Ethernet/IP)

The connected device must be certified in accordance with EN 60950-1.

The maximum permissible cable length of the connected interface is

100 m.

5.9.3.5 KLI IT interface

Description

The KLI IT interface can be used for connection to an IT network. The fol-
lowing options are thus available:
• Backup and update services
• Edge or cloud services, e.g. dashboards for condition monitoring
• Acquisition of messages
• Creation of logbooks
• Detection of anomalies
• Predictive maintenance
The interface is activated via the software (default: not active).
The connected device must be certified in accordance with EN 60950-1.

The maximum permissible cable length of the connected interface is

100 m.

5.9.3.6 KEI interface

Description

EtherCAT slaves outside of the robot controller are connected via the KEI
interface. The EtherCAT line is routed out of the robot controller.

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Bus couplers (e.g. for EtherCAT, Profibus, DeviceNet) can be operated via
Planning

the KEI interface in order to connect the controller to a PLC or bus termi-
nals via these bus couplers. If an EtherCAT coupler is used, a safe FSoE
connection to a PLC can be established via the KEI interface.
The EtherCAT devices must be configured with WorkVisual.

5.9.4 XGDP interface

Description

An external monitor can be connected via the XGDP interface for service
purposes. The XGDP interface provides no safe outputs. The information
displayed must not be used for safety-relevant measures.
VGA support is possible via DP on VGA adapter.

The connected device must be certified in accordance with EN 60950-1.

The maximum permissible cable length of the connected interface is

5 m.

5.9.5 XG12 digital I/O interfaces

Description

The I/O interface XG12 has 16 non-safe inputs and 16 non-safe outputs:
• 16 inputs that can operate both NPN and PNP sensors
• 16 outputs that can operate both NPN and PNP actuators
The inputs and outputs can be configured in groups of 8 from high-side
mode to low-side mode.
• A jumper from pin 1 to pin 2 switches inputs 1 - 8 to low-side mode.
• A jumper from pin 3 to pin 4 switches inputs 9 - 16 to low-side mode.
• A jumper from pin 5 to pin 6 switches outputs 1 - 8 to low-side mode.
• A jumper from pin 7 to pin 8 switches outputs 9 - 16 to low-side
mode.
Default: high-side
Power is supplied via interface XD12.

Necessary equipment

• Connector: Phoenix 40-contact

• Cable clamping range: 0.2 - 1.5 mm2
• Recommended cable cross-section: 0.5 mm2

Contact diagram

Fig. 5-15: Contact diagram, view from contact side

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Connector pin allocation

Pin Description
1 IN_Config 1-8
2 Channels are configurable (depending on the
position of the jumper)
3 IN_Config 9-16
4 Channels are configurable (depending on the
position of the jumper)
5 OUT_Config 1-8
6 Channels are configurable (depending on the
position of the jumper)
7 OUT_Config 9-16
8 Channels are configurable (depending on the
position of the jumper)
9 - 39 IN 1 ... IN 16
All odd pin numbers Digital inputs 1 - 16
10-40 OUT 1 ... OUT 16
All even pin numbers Digital outputs 1 - 16 (output current = 0.5 A)

High-side mode

Switching level of the in- The state for the inputs is not defined for
puts the voltage range from 5 V to 11 V (tran-
sition range). Either the ON state or the
OFF state is set.

• Signal Off / 0:
OFF state for the voltage range from
-3 V to 5 V (OFF range).
• Signal On / 1:
ON state for the voltage range from
11 V to 30 V (ON range).
Load current at the input 3 … 11 mA
(Signal On / 1)

Low-side mode

Switching level of the in- The state for the inputs is not defined for
puts the voltage range from 7 V to 18 V (tran-
sition range). Either the ON state or the
OFF state is set.

• Signal Off / 0:
OFF state for the voltage range from
18 V to 30 V (OFF range).
• Signal On / 1:
ON state for the voltage range from
0 V to 7 V (ON range).
Load current at the input -2 … -8 mA
(Signal On / 1)

Power may only be supplied via a safely isolated PELV/SELV power

supply unit according to EN 60950-1 with a rated voltage of 24 V ±10%.

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The maximum permissible cable length of a connected interface is

50 m.

5.9.6 XD12 and XD12.1 power supply interfaces

Description

The 24 V supply voltage for non-safe I/Os is supplied via interfaces XD12
and XD12.1.

Necessary equipment

• Cable clamping range: 0.35 - 2.5 mm2

• Recommended cable cross-section: 1.5 mm2

Contact diagram

Fig. 5-16: Contact diagram, view from contact side

Connector pin allocation XD12 and XD12.1

Pin Description
1 XD12
0 V external
2 XD12
+24 V external
3 XD12.1
0 V external
4 XD12.1
+24 V external

Power may only be supplied via a safely isolated PELV/SELV power

supply unit according to EN 60950-1 with a rated voltage of 24 V ±10%.

The 24 V supply voltage must be protected with a maximum fuse of

10 A.

5.9.7 XD2 UPS interface

Description

The robot controller has an uninterruptible power supply (UPS) which ena-
bles the robot controller to be shut down safely in a controlled manner in
the event of a power failure or if the power is switched off. The integrated
UPS circuit requires a 24 V power supply for this. The power supply can
be provided via a central 24 V connection or via an externally connected
battery. Once the mains power supply is restored, the external battery is

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Planning
bot controllers with 24 V in the event of a power failure.
NOTICE
Data loss due to operation of the robot controller without UPS
It must be ensured that the UPS is operational, otherwise the robot con-
troller must not be operated. Operating the robot controller without the
UPS may result in data loss.
• Connect the power supply of the UPS to a central 24 V ±10% con-
nection or an external battery.

A daisy chain to the previous robot controller can additionally be con-

nected to interface XD2 in order to loop through the signals.

Necessary equipment

• Weidmüller connector
• Cable clamping range: 0.14 - 1.5 mm2
• Recommended cable cross-section: 1.5 mm2

Fig. 5-17: Contact diagram, view from contact side

Connector pin allocation

Pin Description
1D/1U UPS_SYNC
2D/2U PSU_GND
3D/3U UPS_27V1
+27 V power infeed, system side
4D/4U UPS_GND
Power infeed, system side

Wiring examples with central 24 V connection

The following options are available for power supply via a central 24 V
connection:

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Fig. 5-18: Operation with up to 3 robot controllers

1 Central 24 V connection
2 Robot controller 1
3 Robot controller 2
4 Robot controller 3
Operation of a single robot controller with power supply via a central 24 V
connection:

Fig. 5-19: Operation with one robot controller

1 Central 24 V connection
2 Robot controller

PSU_GND and UPS_GND are different potentials and must not be con-
nected to one another.

Power may only be supplied via a safely isolated PELV/SELV power

supply unit according to EN 60950-1 with a rated voltage of 24 V ±10%.

The maximum permissible cable length of a connected interface is

50 m.

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If using UPS batterypack 24V: Detailed information is contained in the
UPS batterypack 24V documentation.

5.9.8 Safety interfaces

5.9.8.1 Interface XG58, external enabling switch

Description

Interface XG58 has one safe input for connecting the external enabling
switch and one safe input for connecting an additional EMERGENCY
STOP.
Pressing the enabling switch enables motion enable of the drives. If the
enabling button is held down in the central position, the axes can be
moved to the corresponding position.

Fig. 5-20: External enabling switch

1 Enabling button 2 Enabling switch

Enabling device

The external enabling signal is transferred to the controller by actuating

the enabling button. The function has 3 positions:
• Not pressed
• Center position
• Fully pressed (panic position)
The kinematic system can only be moved if the enabling switch is actu-
ated and the enabling button is held down in the central position.
Releasing it or pressing it down fully triggers a safety stop 2.
NOTICE
The max. number of switching cycles of the external enabling switch is
20000.

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WARNING
Danger to life and limb due to incorrect enabling switch
Only the external enabling switch specified by KUKA Deutschland
GmbH may be connected. Non-compliance can result in death, serious
injury or damage to property.
• Only connect the external enabling switch with the article number
358565.

Necessary equipment

• Connector: Phoenix 1053810

• Cable clamping range: 0.2 - 1.5 mm2
• Recommended cable cross-section: 0.5 mm2

Contact diagram

Fig. 5-21: Contact diagram

Connector pin allocation XG58

The connector bypack XG58 is delivered with the signals “External ena-
bling” and “Local EMERGENCY STOP” jumpered.

Pin Signal Description Function

5 TA_A External enabling For connection of an
1 IN_A2 (channel A) external dual-channel
enabling switch with
3 TA_B External enabling floating contacts (Only
7 IN_B2 (channel B) effective in TEST
modes.)
If no external enabling
switch is connected,
pins 5/1 and 3/7 must
be jumpered.
6 TA_A Local EMERGENCY For connection of an
2 IN_A3 STOP (channel A) additional 2-channel
external EMERGENCY
4 TA_B Local EMERGENCY STOP device with
8 IN_B3 STOP (channel B) floating contacts. If no
additional external
EMERGENCY STOP
device is connected,
pins 6/2 and 4/8 must
be jumpered.

Function of external axis enabling switch

• External enabling switch

Enabling switch must be pressed for jogging in T1 or T2. Input is
closed.

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Planning
• If a smartPAD is connected, its enabling switches and the external en-
abling are ANDed.

Function External enabling

Switch position
(only active for T1 and T2) switch
Safety stop 2 (safe operational stop, drives Input open Not actuated or panic
switched on) position
Axes enabled (axis jogging possible) Input closed Center position

5.9.8.2 Safety interface XG11.1

Description

2 safe inputs and 1 safe output are made available via safety interface
XG11.1. EMERGENCY STOP devices must be connected via safety inter-
face XG11.1 or linked together by means of higher-level controllers (e.g.
PLC).
Take the following points into consideration when wiring safety interface
XG11.1:
• System concept
• Safety concept

Necessary equipment

• Phoenix 1053815 connector

• Cable clamping range: 0.2 - 1.5 mm2
• Recommended cable cross-section: 0.5 mm2

Contact diagram

Fig. 5-22: Contact diagram

Connector pin allocation

Pin Description
1 External EMERGENCY STOP
IN_A0
2 Operator safety
IN_A1
3 External EMERGENCY STOP
TA_B
4 Operator safety
TA_B
5 External EMERGENCY STOP
TA_A

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Pin Description
7 External EMERGENCY STOP
IN_B0
8 Operator safety
TA_A
10 Operator safety
IN_B1
11 Local EMERGENCY STOP (floating contact)
KL23_A
14 Local EMERGENCY STOP (floating contact)
KL34_B
15 Local EMERGENCY STOP (floating contact)
KL33_B
16 Local EMERGENCY STOP (floating contact)
KL24_A

The voltage switched with the safe outputs must be generated through
a safely isolated PELV power supply unit according to EN 60950-1 with
a rated voltage of 24 V ± 10%.
The following conditions must be met:
• Maximum load voltage at the power contacts: 30 V DC
• Load current per power contact : min. 10 mA DC
• Maximum load current per power contact: 750 mA DC
• If an inductive load is connected, an arc quenching device must be
used to protect the contacts.

The maximum permissible cable length of a connected interface is

50 m.

5.9.8.3 Wiring examples for safe inputs and outputs

Safe input

The switch-off capability of the inputs is monitored cyclically.

The inputs 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 float-
ing contact provided by the customer.

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Fig. 5-23: Connection schematic for safe input

1 Robot controller
2 SCU-6-1S
3 Interface XG11.1 or XG58
4 Input X, channel A (IN_A[x])
5 Input X, channel B (IN_B[x])
6 Test output channel B (TA_B)
7 Test output channel A (TA_A)
8 Interface XG11.1
9 System side
10 Floating contact, input X
Test outputs A and B are supplied with power internally via the power
supply unit on the FCU. Test outputs A and B are sustained short-circuit
proof. The test outputs must only be used as described in (>>> Fig. 5-23)
and are not permitted for any other purpose.
The wiring example described can be used to achieve compliance with
Category 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 outputs TA_A and TA_B are switched off alternately.
• The switch-off pulse length is set to 600 µs.
• The duration t2 between two switch-off pulses on one channel is
< 1 s.
• The input channel IN_A[x] must be supplied by the test signal TA_A.
The input channel IN_B[x] must be supplied by the test signal TA_B.
No other power supply is permissible.
• It is only permitted to connect sensors which allow the connection of
test signals and which provide floating contacts.
• The signals TA_A and TA_B must not be significantly delayed by the
switching element.

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Switch-off pulse diagram

Fig. 5-24: Switch-off pulse diagram, test outputs

t1 Switch-off pulse length (600 µs)

t2 Switch-off period per channel (< 1 s)
t3 Offset between switch-off pulses of both channels
(50 ms)
TA_A Test output channel A
TA_B Test output channel B
IN_A[x] Input X, channel A
IN_B[x] Input X, channel B

Safe output

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 customer must be monitored externally for cross-connection.

Fig. 5-25: Connection schematic for safe output

1 Robot controller
2 Interface XG11.1
3 Output wiring
4 Interface XG11.1
5 System side
6 Safe input
7 Test output channel A

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8 Test output channel B
9 Input X, channel B
10 Input X, channel A
The wiring example described can be used to achieve compliance with
Category 3 and Performance Level (PL) d according to EN ISO 13849-1.

5.9.9 Safety functions via Ethernet safety interface (optional)

Description

The exchange of safety-relevant signals between the controller and the

system 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 information from the safety controller is sent to the non-safe sec-
tion of the higher-level controller for the purpose of diagnosis and control.

Reserved bits

Reserved safety-oriented inputs can be pre-assigned by a PLC with the

values 0 or 1. In both cases, the manipulator will move. If a safety func-
tion is assigned to a reserved input (e.g. in the case of a software update)
and if this input is preset with the value 0, then the manipulator either
does not move or comes unexpectedly to a standstill.
KUKA recommends pre-assignment of the reserved inputs with 1. If a
reserved input has a new safety function assigned to it, and the input is
not used by the customer’s PLC, the safety function is not activated.
This prevents the safety controller from unexpectedly stopping the ma-
nipulator.

Input byte 0

Bit Signal Description

0 RES Reserved 1
The value 1 must be assigned to the input.
1 NHE Input for external Emergency Stop
0 = external E-STOP is active
1 = external E-STOP is not active
2 BS Operator safety
0 = operator safety is not active, e.g. safety gate
open
1 = operator safety is active

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Bit Signal Description

3 QBS Acknowledgement of operator safety
Precondition for acknowledgment of operator safety
is the signal "Operator safety active" set in the BS
bit.
Note: If the “BS” signal is acknowledged by the
system, this must be specified under Hardware op-
tions in the safety configuration. Information is con-
tained in the Operating and Programming Instruc-
tions for System Integrators.
0 = operator safety has not been acknowledged
Edge 0 ->1 = operator safety has been acknowl-
edged
4 SHS1 Safety STOP 1 (all axes)

• FF (motion enable) is set to 0.

• Voltage US2 is switched off.
• AF (drives enable) is set to 0 after 1.5 s.
Cancelation of this function does not require ac-
knowledgement.
This function is not permissible for the EMERGEN-
CY STOP function.
0 = safety stop is active
1 = safety stop is not active
5 SHS2 Safety STOP 2 (all axes)

• FF (motion enable) is set to 0.

• Voltage US2 is switched off.
Cancelation of this function does not require ac-
knowledgement.
This function is not permissible for the EMERGEN-
CY STOP function.
0 = safety stop is active
1 = safety stop is not active
6 RES -
7 RES -

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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
configuration. Information is contained in the Oper-
ating and Programming Instructions for System Inte-
grators.
1 SBH Safe operational stop (all axes)
Prerequisite: All axes are stationary
Cancelation of this function does not require ac-
knowledgement.
This function is not permissible for the EMERGEN-
CY 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.
4 RES Reserved 13
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.
7 SPA System Powerdown Acknowledge
The system confirms that it has received the power-
down signal. A second after the “SP” (System Pow-
erdown) signal has been set by the controller, the
requested action is executed, without the need for
confirmation from the PLC, and the controller shuts
down.
0 = confirmation is not active
1 = confirmation is active

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Output byte 0

Bit Signal Description

0 NHL Local E-STOP (local E-STOP triggered)
0 = local E-STOP is active
1 = local E-STOP is not active
1 AF Drives enable (the internal safety controller of the
robot controller has enabled the drives so that they
can be switched on)
0 = drives enable is not active (the robot controller
must switch the drives off)
1 = drives enable is active (the robot controller
must switch the drives to servo-control)
2 FF Motion enable (the internal safety controller of the
robot controller has enabled robot motions)
0 = motion enable is not active (the robot controller
must stop the current motion)
1 = motion enable is active (the robot controller
may trigger a motion)
3 ZS The signal ZS (enabling) is set to 1 (active) if the
following conditions are met:

• One of the enabling switches on the smartPAD

is in the center position (enabling signal has
been issued).
• T1 or T2 mode
• External enabling signal has been issued (signal
ZSE1/ZSE2).
• Robot can be moved (no external
EMERGENCY STOP, safety stop, etc.).
4 PE The signal “Peri enabled” is set to 1 (active) if the
following conditions are met:

• Drives are switched on.

• Safety controller motion enable signal present.
• The message “Operator safety open” must not
be active.

5 AUT The manipulator is in AUT or AUT EXT mode.

0 = AUT or AUT EXT mode is not active
1 = AUT or AUT EXT mode is active
6 T1 The manipulator is in Manual Reduced Velocity
mode.
0 = T1 mode is not active
1 = T1 mode is active
7 T2 The manipulator is in Manual High Velocity mode.
0 = T2 mode is not active
1 = T2 mode is active

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Output byte 1

Bit Signal Description

0 NHE External E-STOP has been triggered.
0 = external E-STOP is active
1 = external E-STOP is not active
1 BSQ Operator safety acknowledged
0 = operator safety is not assured
1 = operator safety is assured (input BS = 1 and,
if configured, input QBS acknowledged)
2 SHS1EXT External safety STOP 1 (all axes)
0 = external safety STOP 1 is not active
1 = external safety STOP 1 is active (input SHS1
= 0, safe state reached)
3 SHS2EXT External safety STOP 2 (all axes)
0 = external safety STOP 2 is not active
1 = external safety STOP 2 is active (input SHS2
= 0, safe state reached)
4 RES Reserved 13
5 RES Reserved 14
6 PSA Safety interface active
Precondition: an Ethernet interface must be instal-
led on the controller, e.g. PROFINET or
EtherNet/IP.
0 = safety interface is not active
1 = safety interface is active
7 SP System Powerdown (controller will be shut down)
One second after the SP signal has been set, the
PSA output is reset by the robot controller, without
confirmation from the PLC, and the controller is
shut down.
0 = controller on safety interface is active.
1 = controller will be shut down

5.9.10 XG33 Fast Measurement inputs

Description

Fast Measurement interface XG33 can be used to program commands in

the robot controller for measuring workpieces using digital sensors.
Additionally, the “Drives ready” lamp can be connected via interface XG33.
Interface XG33 is located on the connection panel of the robot controller.

Necessary equipment

• Connector: Phoenix 1053810

• Cable clamping range: 0.2 - 1.5 mm2
• Recommended cable cross-section: 0.5 mm2

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Contact diagram

Fig. 5-26: Contact diagram

Connector pin allocation

Pin Description
1 +27 V, max. 400 mA
2 PSU GND
3 Fast Measurement 1
4 Fast Measurement 2
5 Fast Measurement 3
7 +24 V
“Drives ready” lamp connection (optional)
8 0 V
“Drives ready” lamp connection (optional)

Fast Measurement inputs

Switching level of the in- The state for the inputs is not defined for
puts the voltage range from 5 V to 11 V (tran-
sition range). Either the ON state or the
OFF state is set.

• Signal Off / 0:
OFF state for the voltage range from
-3 V to 5 V (OFF range).
• Signal On / 1:
ON state for the voltage range from
11 V to 30 V (ON range).
Load current at the input 6 … 13 mA
(Signal On / 1)

The maximum permissible cable length of a connected interface is

50 m.

5.9.10.1 Power supply for Fast Measurement

Description

The sensors for Fast Measurement are supplied with power internally via
XG33.

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Fig. 5-27: Fast Measurement and “Drives ready” lamp

1 Robot controller XG33 4 Sensor 2

2 System side 5 Sensor 3
3 Sensor 1 6 “Drives ready” lamp (optional)

5.9.11 Connecting data cables XF21

Description

Communication to the RDC box is carried out via interface XF21.

Additionally, the interface provides the voltage for supplying the RDC box
and the I/O interface on the robot.

Fig. 5-28: Contact diagram

Connector pin allocation XF21

Pin Description
1 EtherCAT connection
LAN_RX+
2 EtherCAT connection
LAN_RX-
3 EtherCAT connection
LAN_TX+
4 EtherCAT connection
LAN_TX-
5 +27 V / 3 A
PSU_27V1_OUT_IO
Additional power supply

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Pin Description
6 PSU_GND
Additional power supply
7 +27 V
PSU_27V1_OUT_POS
Power supply for RDC (with battery backup)
8 PSU_GND
Power supply for RDC (with battery backup)
Shield PE

The maximum permissible cable length of a connected interface is

50 m.

5.9.12 XD20.1 and XD20.2 motor interface

Description

The motors and brakes of the robot axes are connected to the robot con-
troller via motor connectors XD20.1 and XD20.2. The two motor connec-
tors are identical in design and are distinguished from one another by dif-
ferent non-interchangeable codings (type A and type B).

Contact diagram

Fig. 5-29: Contact diagram

1 Coding for XD20.1 (type A)

2 Coding for XD20.2 (type B)

Connector pin allocation XD20.1

Pin Description
16d Motor M3 U1
16z Motor M3 V1
12d Motor M3 W1
12z Motor M2 U1
10d Motor M2 V1
10z Motor M2 W1
8d Motor M1 U1
8z Motor M1 V1
6d Motor M1 W1
6z PE

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Pin Description
2d Brake, axes 1-3, 24 V
2z Brake, axes 1-3, GND
14z PE
4z PE

Connector pin allocation XD20.2

Pin Description
16d Brake, axes 4-6, 24 V
16z Brake, axes 4-6, GND
12d Motor M4 U1
12z PE
10d Motor M4 V1
10z Motor M4 W1
8d Motor M5 U1
8z Motor M5 V1
6d Motor M5 W1
6z Motor M6 U1
2z Motor M6 W1
2d Motor M6 V1
14z PE
4z PE

5.10 Performance level

The safety functions of the robot controller conform to Category 3 and

Performance Level d according to EN ISO 13849-1.

5.10.1 PFH values of the safety functions

The safety values are based on a service life of 20 years.

The PFH value classification of the controller is only valid if the EMER-
GENCY STOP device and the enabling switches on the smartPAD are
tested at least once every 12 months.
When evaluating system safety functions, it must be remembered that the
PFH values for a combination of multiple controllers may have to be taken
into consideration more than once. This is the case for RoboTeam sys-
tems or higher-level hazard areas. The PFH value determined for the
safety function at system level must not exceed the limit for PL d.
The PFH values relate to the specific safety functions of the different con-
troller variants.
Safety function groups:

• Standard safety functions

‒ Operating mode selection
‒ Operator safety
‒ EMERGENCY STOP device
‒ Enabling device

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‒ External safe operational stop

‒ External safety stop 1
‒ External safety stop 2
‒ Velocity monitoring in T1
• Safety functions of KUKA Safe Robot Technology (optional)
‒ Monitoring of axis spaces
‒ Monitoring of Cartesian spaces
‒ Monitoring of axis velocity
‒ Monitoring of Cartesian velocity
‒ Monitoring of axis acceleration
‒ Safe operational stop
‒ Tool monitoring
Overview of controller variant PFH values:
Robot controller variant PFH value
KR C5 micro < 1 x 10-7

For controller variants that are not listed here, please contact KUKA
Deutschland GmbH.

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Transportation
6 Transportation

6.1 Transportation with trolley

Preconditions

• The housing of the robot controller must be closed.

• No cables may be connected to the robot controller.

Procedure

• Transport the robot controller horizontally on a trolley.

NOTICE
Damage to property due to incorrect transportation
The robot controller must be protected from excessive shock loads dur-
ing transportation. The load limits must not be exceeded during trans-
portation.
• If more severe mechanical stress is expected, the robot controller
must be installed on anti-vibration components.

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Start-up and recommissioning

7 Start-up and recommissioning

7.1 Start-up overview

This is an overview of the most important steps during start-up. The

precise sequence depends on the application, the manipulator type, the
technology packages used and other customer-specific circumstances.
For this reason, the overview does not claim to be comprehensive.

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

Step Description Information

1 Carry out a visual inspection of the manipula-Detailed information is contained
tor. in the operating or assembly in-
2 Install the manipulator mounting base (mount- structions for the manipulator, in
ing base, machine frame mounting or booster the chapter “Start-up and recom-
frame). missioning”.

3 Install the manipulator.

Electrical system

Step Description Information

4 Carry out a visual inspection of the robot con- -
troller.
5 Make sure that no condensation has formed -
in the robot controller.
6 Install the strain relief device. (>>> 10.1.1 "Installing the strain
relief device" Page 111)
7 Install the robot controller. (>>> 7.2 "Installing the robot con-
troller" Page 99)
8 Connect the equipotential bonding between (>>> 5.5 "PE equipotential bond-
the manipulator and the robot controller. ing" Page 64)
9 Connect the connecting cables. (>>> 7.3 "Connecting the con-
necting cables and ground con-
ductor" Page 100)
10 Plug in the KUKA smartPAD. (>>> 7.4 "Plugging in the KUKA
smartPAD" Page 101)
11 Connect the robot controller to the power (>>> 7.5 "Connecting the mains
supply. power supply" Page 101)
12 Connect 24 V for UPS. (>>> 7.6 "Connecting the UPS"
Page 101)
13 Configure and connect safety interface (>>> 7.7 "Configuring and con-
XG11.1. necting safety interface XG11.1"
Page 102)
14 Connect interface XG58. (>>> 7.8 "Configuring and con-
necting safety interface XG58"
Page 102)
15 Connect Ethernet and EtherCAT interfaces. (>>> 5.9.3 "Interfaces XF1 - XF8"
Page 71)

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Step Description Information

16 Connect optional interfaces. -
17 Switch on the robot controller. (>>> 7.9 "Switching on the robot
controller" Page 102)
18 Establish connection to WorkVisual. Detailed information is contained
in the “Start-up” chapter of the
WorkVisual documentation.
19 Configure the inputs/outputs between the ro- Detailed information is contained
bot controller and the periphery. in the “Configuration of the KUKA
buses” chapter of the WorkVisual
documentation.
20 Check the safety equipment. Detailed information is contained
in the operating and assembly in-
structions for the robot controller,
in the “Safety” chapter.

Software

Step Description Information

21 Check the machine data. Detailed information is contained
22 Master the manipulator without a load. in the operating and programming
instructions.
23 Mount the tool and master the manipulator
with a load.
24 Check the software limit switches and adapt
them if required.
25 Calibrate the tool.
In the case of a fixed tool: calibrate external
TCP.
26 Enter the load data.
27 Calibrate the base (optional).
In the case of a fixed tool: calibrate
workpiece (optional).
28 If the manipulator is to be controlled by a Detailed information is contained
host computer or PLC: configure the Automat- in the Operating and Program-
ic External interface. ming Instructions for System Inte-
grators.

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 Detailed information can be found
system, taking the programming into consideration. in the energy supply system doc-
umentation.
Positionally accurate manipulator option: check data.

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7.2 Installing the robot controller

Description

The robot controller can be operated if the following installation conditions

are met:
• Horizontal position as standalone variant, with or without holders
• Vertical position as standalone variant, with holders
• Stackable using holders
• Insertion in 19" rack
• Installation on a mounting plate as panel-mounted variant, or directly
on a wall
‒ Flat installation on wall (>>> Fig. 5-5)
‒ Vertical installation on wall (>>> Fig. 5-6)

Precondition

• The minimum clearances to walls, other cabinets, etc. must be ob-

served. (>>> 5.3 "Installation conditions" Page 58)
• In the case of installation on a wall or mounting plate, the dimensions
of the drilling templates must be observed. (>>> 5.4 "Installation with
holders" Page 62)
• In the case of installation on a wall or mounting plate, the minimum
clearances must be observed and it must be ensured that all switches
and connectors are freely accessible.
• In the case of installation on a wall or mounting plate, it must be en-
sured that the air inlet for cooling is on the underside.
• In the case of installation on a wall or mounting plate, it must be en-
sured that there is a clear view of the front side of the robot controller.

NOTICE
Damage to property due to build-up of discharged heat
If the heat discharged by the robot controller is not dissipated, this may
lead to unintentional shutdowns or a shortened service life of the robot
controller.
• Position the robot controller in such a way that the discharged heat
cannot accumulate.

Procedure

1. Check the robot controller for any damage caused during transporta-
tion.
2. Depending on the installation position, mount the 4 holders on both
sides of the robot controller.

Fig. 7-1: Installing the holders (example)

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3. Install the robot controller. (>>> 5.3 "Installation conditions" Page 58)

7.3 Connecting the connecting cables and ground conductor

DANGER
Risk of injury due to damaged cables
Cables can be damaged if not installed correctly. Death, injuries or dam-
age to property may result.
• Route electric cables in such a way that they cannot be damaged
by sharp edges, tools or other materials.

CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.

Overview

A cable set is supplied with the robot system. In the standard version the
cable set consists of:
• Motor cable
• Data cable
• Power supply cable
(>>> 5.8 "Power supply connection" Page 67)
• Connector bypack for standard interfaces (data/safety interfaces)
(>>> 5.9 "Overview of interfaces" Page 67)

Ground conductor is not included in the cable set, but must be connec-
ted.
(>>> 5.5 "PE equipotential bonding" Page 64)

Fig. 7-2: Connecting cables, connection to robot

Procedure

1. Connect the ground conductor. (>>> 5.5 "PE equipotential bonding"

Page 64)
2. Connect the data cable and motor cable.

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7.4 Plugging in the KUKA smartPAD

Description

The KUKA smartPAD is connected to interface XG19.

Procedure

• Plug the KUKA smartPAD into XG19 on the robot controller.

WARNING
Risk of fatal injury due to non-operational EMERGENCY STOP de-
vice
If the smartPAD is disconnected, the system can no longer be switched
off by means of the EMERGENCY STOP device on the smartPAD.
Measures must be taken to prevent operational and non-operational
EMERGENCY STOP devices from being mixed up.
Death, injuries or damage to property may result.
• Connect an external EMERGENCY STOP to the robot controller.
• Remove the disconnected smartPAD from the system immediately.

The function test for all enabling switches must be carried out before
start-up and at least once every 12 months.

7.5 Connecting the mains power supply

Description

The robot controller may only be connected to the mains via the device
connection cable included in the scope of supply or the mains connector
included in the scope of supply.

Precondition

• The robot controller is switched off.

• The power cable is deenergized.

Procedure

• Connect the robot controller to the power supply via XD1.

7.6 Connecting the UPS

Description

Operation of the uninterruptible power supply (UPS) requires the connec-

tion of an external 24 V power supply to the robot controller. The following
options are available:
• Connection via an externally connected battery (UPS batterypack 24V)
• Connection via a central 24 V connection

If using UPS batterypack 24V: Detailed information is contained in the

UPS batterypack 24V documentation.

Precondition

• The robot controller is switched off.

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Procedure

• Connect 24 V power supply to the robot controller via XD2.

7.7 Configuring and connecting safety interface XG11.1

Precondition

• The robot controller is switched off.

Procedure

1. Configure connector XG11.1 in accordance with the system and safety

concepts. (>>> 5.9.8.2 "Safety interface XG11.1" Page 81)
2. Connect interface connector XG11.1 to the robot controller.

NOTICE
Damage to property due to plugging or unplugging of live connec-
tors
Connector XG11.1 may only be plugged in or unplugged when the robot
controller is switched off. If connector XG11.1 is plugged in or unplug-
ged when energized, damage to property may occur.
• Switch the robot controller off.

7.8 Configuring and connecting safety interface XG58

Precondition

• The robot controller is switched off.

Procedure

1. Configure connector XG58 in accordance with the system and safety

concepts. (>>> 5.9.8.1 "Interface XG58, external enabling switch"
Page 79)
2. Connect interface connector XG58 to the robot controller.

NOTICE
Damage to property due to plugging or unplugging of live connec-
tors
Connector XG58 may only be plugged in or unplugged when the robot
controller is switched off. If connector XG58 is plugged in or unplugged
when energized, damage to property may occur.
• Switch the robot controller off.

7.9 Switching on the robot controller

Preconditions

• The manipulator has been installed in accordance with the operating

instructions.
• Visual inspection: The robot controller, cables and manipulator are un-
damaged.
• All electrical connections are correctly connected and secured at the
strain relief device to prevent unintentional disconnection.
• The housing of the robot controller is closed.
• The peripheral devices are correctly connected.

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• It must be ensured that no persons or objects are present within the
danger zone of the manipulator.
• All safety devices and protective measures are complete and fully
functional.
• The internal temperature of the robot controller must have adapted to
the ambient temperature.

Procedure

1. Release the EMERGENCY STOP device on the smartPAD.

2. Switch on the device switch.
The control PC begins to run up (load) the operating system and the
control software.

Further information about the functions and operator control of the

smartPAD-2 can be found in the operating instructions of the smart-
PAD-2 and in the operating and programming instructions of the KUKA
System Software.

7.10 Concluding work

The following concluding work must be carried out:

• Move the manipulator and look out for irregularities.

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Operation
8 Operation

8.1 Switching on the robot controller

Preconditions

• The manipulator has been installed in accordance with the operating

instructions.
• Visual inspection: The robot controller, cables and manipulator are un-
damaged.
• All electrical connections are correctly connected and secured at the
strain relief device to prevent unintentional disconnection.
• The housing of the robot controller is closed.
• The peripheral devices are correctly connected.
• It must be ensured that no persons or objects are present within the
danger zone of the manipulator.
• All safety devices and protective measures are complete and fully
functional.
• The internal temperature of the robot controller must have adapted to
the ambient temperature.

Procedure

1. Release the EMERGENCY STOP device on the smartPAD.

2. Switch on the device switch.
The control PC begins to run up (load) the operating system and the
control software.

Further information about the functions and operator control of the

smartPAD-2 can be found in the operating instructions of the smart-
PAD-2 and in the operating and programming instructions of the KUKA
System Software.

8.2 Function of soft power button

Description

• Pressing briefly while robot controller is switched on:

The robot controller shuts down.
• Pressing briefly if the robot controller is in cold start, sleep mode (hi-
bernate) or energy-saving mode:
The robot controller is restarted.
• Pressing for longer (at least 5 seconds) while robot controller is
switched on:
The robot controller carries out a hard power-off without shutting
down.
A hard power-off of the robot controller should be avoided. Powering
off without a normal shutdown can destroy the installation.

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Maintenance
9 Maintenance
Description

Maintenance work must be performed at the specified maintenance inter-

vals after commissioning at the customer’s plant.

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Wait 5 minutes until the intermediate circuit has discharged.
WARNING
Danger to life and limb due to high intermediate circuit voltages
Some components may remain energized (60 … 450 V) up to 5 mi-
nutes after the robot controller has been switched off. Death, severe
injuries or damage to property may result.
‒ After switching off, wait at least 5 minutes until the intermediate
circuit has discharged.
The following components may remain energized for up to 5 mi-
nutes:
‒ KSP-300
‒ Connections for motor connector and connected motor ca-
bles

Maintenance symbols

The overview may contain maintenance symbols that are not relevant
for the maintenance work on this product. The maintenance illustrations
provide an overview of the relevant maintenance work.

Oil change

Lubricate with grease gun

Lubricate with brush

Lubricate with spray grease

Tighten screw/nut

Check component, visual inspection

Clean component

Exchange battery

Exchange component

Check toothed belt tension

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Fig. 9-1: Maintenance diagram

Interval Item Activity

1 year - Cyclical function test of operator safety and all
EMERGENCY STOP devices (e.g. smartPAD, ex-
ternal EMERGENCY STOP devices, etc.)
- Perform function test of all enabling switches on
the smartPAD.
- Function test of external enabling devices
1 year at 2 Depending on installation conditions and degree of
the latest fouling, clean the protective grille of the fan with a
brush.
10 years 1 Exchange the motherboard battery. (>>> 10.4 "Ex-
changing the motherboard battery" Page 116)
If an activity from the maintenance table is performed, a visual inspection
must be made, with special attention to the following points:
• Check that plug connections are securely fastened.
• Check PE equipotential bonding connection.
• Check all system components for wear and damage.

9.1 Cleaning the robot controller

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Wait 5 minutes until the intermediate circuit has discharged.

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Maintenance
Work safety

WARNING
Danger to life and limb due to high intermediate circuit voltages
Some components may remain energized (60 … 450 V) up to 5
minutes after the robot controller has been switched off. Death, severe
injuries or damage to property may result.
• After switching off, wait at least 5 minutes until the intermediate cir-
cuit has discharged.
The following components may remain energized for up to 5 mi-
nutes:
‒ KSP-300
‒ Connections for motor connector and connected motor cables

WARNING
Risk of fatal injury from voltage
The device switch on the robot controller does not have a grid isolation
function. Failure to take this into consideration may result in severe inju-
ries or even death.
• Before undertaking work on the robot controller, the power cable on
the robot controller must be disconnected.
• Store the disconnected power cable out of sight and reach of per-
sonnel working on the robot controller.
• Use a sign to inform the individuals involved that the robot controller
is switched off (e.g. by affixing a warning sign).

NOTICE
Damage to or destruction of components due to electrostatic dis-
charge (ESD)
Electrostatic discharge during installation or removal work can result in
destruction or partial damage to electronic components.
• Observe the ESD guidelines.

Work regulations

• The manufacturer’s instructions must be observed when using clean-

ing agents for cleaning work.
• It must be ensured that no cleaning agents enter electrical compo-
nents.
• Do not use compressed air during cleaning work.
• Do not spray with water.

Procedure

1. Loosen and vacuum up any dust deposits.

2. Clean the housing of the robot controller with a cloth soaked with a
mild cleaning agent.
3. Clean cables, plastic parts and hoses with a solvent-free cleaning
agent.
4. Replace damaged, illegible or missing identifications, labels and
plates.

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Repair
10 Repair

10.1 Exchanging the strain relief device

Description

The following sections describe the procedure for installation and removal
of the strain relief device on the KR C5 micro.
Plug connections can come loose or angled connectors can break off if
subjected to excessive strain. It is recommended that the cables of all
connectors are fastened to the strain relief device.

Equipment

The following equipment is required:

Designation Article number
TORX screwdriver set TX10 -

Material

The following material is required:

Designation Article number Quantity
Supplied strain relief device with TORX - 1
screws

Work safety

There are no particular safety instructions to be observed.

10.1.1 Installing the strain relief device

Procedure

1. Fasten the strain relief device onto the robot controller with 3 TORX
screws; tightening torque MA= 0.6 Nm.

Fig. 10-1: Strain relief device

1 M3 TORX screws
2 Strain relief device

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10.1.2 Removing the strain relief device

Procedure

1. Remove the cable strap.

2. Unscrew 3 TORX screws from the robot controller.

Fig. 10-2: Strain relief device

1 M3 TORX screws
2 Strain relief device

10.1.3 Concluding work

The following concluding work must be carried out after installation of the
strain relief device:
• Check that the strain relief device is fitted securely.
• Fasten the cables of all connectors to the strain relief device using ca-
ble straps.

10.2 Exchanging the Mounting brackets 19" frame

Description

The following sections describe the procedure for installation and removal
of the Mounting brackets 19" frame on the KR C5 micro.

Equipment

The following equipment is required:

Designation Article number
TORX screwdriver set TX10 -

Material

The following material is required:

Designation Article number Quantity
Mounting brackets 19" frame 0000-346-287 1x

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Repair
Work safety

There are no particular safety instructions to be observed.

10.2.1 Installing the Mounting brackets 19" frame

Procedure

1. Fasten the Mounting brackets 19" frame to the robot controller with 4
TORX screws; tightening torque MA= 0.6 Nm.

Fig. 10-3: Mounting brackets 19" frame

1 Mounting brackets 19" frame

2 Holes
3 Tapped holes

10.2.2 Removing the Mounting brackets 19" frame

Procedure

1. Unscrew 4 TORX screws from the robot controller.

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Fig. 10-4: Mounting brackets 19" frame

1 Mounting brackets 19" frame

2 Holes
3 Tapped holes

10.2.3 Concluding work

The following concluding work must be carried out after installation of the
Mounting brackets 19" frame:
• Check that the Mounting brackets 19" frame is fitted securely.

10.3 Exchanging the SSD hard drive

Description

The following section describes the procedure for exchanging the SSD
hard drive.

Equipment

No equipment is required.

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Material

The following material is required:

Designation Article number Quantity
KR C5 SSD external 60GB 0000-281-418 1x

Work safety

There are no particular safety instructions to be observed.

10.3.1 Removing the SSD hard drive

Procedure

1. Unlock the locking device on the cover of the push-in module. The
cover swings open.

Fig. 10-5: Opening the SSD slot

1 Locking device 2 Cover

2. Open the cover completely. The SSD slot is accessible.

3. Pull out the SSD hard drive.

10.3.2 Installing the SSD hard drive

Procedure

1. Push the new SSD hard drive into the slot as far as it will go.
2. Close the cover. This pushes the SSD hard drive into its final position
and it clicks into place.
3. Lock the cover.

10.3.3 Concluding work

After the SSD hard drive has been exchanged, the following tasks must
be carried out:

Procedure

1. Switch on the robot controller and check the settings.

2. Carry out a function test.

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10.4 Exchanging the motherboard battery

Description

The following sections describe the procedure for exchanging the mother-
board battery.

Equipment

The following equipment is required:

Designation Article number
TORX screwdriver set TX10 -
USB keyboard -

ESD wrist strap 0000-121-401

Material

The following material is required:

Designation Article number Quantity
Lithium metal button cell CR2032 0000-101-677 1x

Procurement of spare parts

Defective components must only be replaced with original spare parts

from KUKA Deutschland GmbH. Non-compliance nullifies warranty and lia-
bility claims.
A “Repair Card” is supplied with the exchange parts. This must be com-
pleted and returned to KUKA Deutschland GmbH together with the defec-
tive component in the following cases.
• Within the warranty period
• If, after consultation with KUKA Deutschland GmbH, an examination of
the defective component by KUKA is required.

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.

Work safety

WARNING
Danger to life and limb when working on live parts
Before commencing work on live parts of the robot system and/or on
electrical systems, measures must be taken to ensure that the 5 safety
rules are followed. It is essential that the 5 safety steps are followed in
the correct order. Death, severe injuries or damage to property may re-
sult.
1. De-energize
2. Secure against unintentional restart
3. Ensure that the system is de-energized
4. Ground and short-circuit the system
5. Cover or erect barriers around neighboring energized parts
Once the work is completed, tools and equipment must be removed and
the measures rescinded in reverse sequence.

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Repair
WARNING
Risk of fatal injury from voltage
The device switch on the robot controller does not have a grid isolation
function. Failure to take this into consideration may result in severe inju-
ries or even death.
• Before undertaking work on the robot controller, the power cable on
the robot controller must be disconnected.
• Store the disconnected power cable out of sight and reach of per-
sonnel working on the robot controller.
• Use a sign to inform the individuals involved that the robot controller
is switched off (e.g. by affixing a warning sign).

NOTICE
Damage to or destruction of components due to electrostatic dis-
charge (ESD)
Electrostatic discharge during installation or removal work can result in
destruction or partial damage to electronic components.
• Observe the ESD guidelines.

10.4.1 Removing the housing cover

Procedure

1. Undo 4 TORX screws.

Fig. 10-6: Housing cover screws

1 TORX screws

2. Open the housing cover.

3. Remove the plug connection from the controller.

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Fig. 10-7: Housing cover cable

1 Plug connection

10.4.2 Removing the motherboard battery

Procedure

1. Push the retaining spring on the battery holder upwards with a small
flat-blade screwdriver and remove the battery.

Fig. 10-8: Lithium button cell

1 Battery

10.4.3 Inserting the motherboard battery

Procedure

1. Label the new battery with the installation date and insert it into the
battery holder. When the battery is inserted, the retaining spring must
click into place.

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Fig. 10-9: Lithium button cell

1 Battery

10.4.4 Installing the housing cover

Procedure

1. Insert the plug connection into the robot controller.

Fig. 10-10: Housing cover cable

1 Plug connection

2. Place the housing cover on the robot controller.

3. Fasten the housing cover onto the robot controller with 4 TORX
screws; tightening torque MA= 0.6 Nm.

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Fig. 10-11: Housing cover screws

1 TORX screws (4x)

10.4.5 Concluding work

After the battery has been exchanged, the following tasks must be carried
out:

Procedure

1. Plug in USB keyboard.

2. Open BIOS menu.
3. Set date and time.
4. Load default values.
5. Carry out a function test.

10.5 Exchanging the incoming supply fuse

Description

The following section describes the procedure for exchanging fuses F1

and F2 on the rear side of the robot controller.

Equipment

The following equipment is required:

Designation Article number
Flat-blade screwdrivers -

Material

The following material is required:

Designation Article number Quantity
Fuse t 10a (Minimum 10 pc. 0069-000-767 1x

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Repair
Procurement of spare parts

Defective components must only be replaced with original spare parts

from KUKA Deutschland GmbH. Non-compliance nullifies warranty and lia-
bility claims.
A “Repair Card” is supplied with the exchange parts. This must be com-
pleted and returned to KUKA Deutschland GmbH together with the defec-
tive component in the following cases.
• Within the warranty period
• If, after consultation with KUKA Deutschland GmbH, an examination of
the defective component by KUKA is required.

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.

NOTICE
Damage to or destruction of components due to electrostatic dis-
charge (ESD)
Electrostatic discharge during installation or removal work can result in
destruction or partial damage to electronic components.
• Observe the ESD guidelines.

10.5.1 Exchanging the incoming supply fuse

Procedure

1. Switch off and disconnect the robot controller.

2. Open the cover of the defective fuse with a screwdriver and pull it out
of the housing.
3. Exchange the fuse and reinstall.

10.5.2 Concluding work

After the fuses have been exchanged, the following tasks must be carried
out:

Procedure

• Switch on the robot controller and check that it boots flawlessly.

• Execute the program in T1 mode.

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Troubleshooting
11 Troubleshooting

11.1 KSP warning messages

Description

The warning messages have corresponding acknowledgement messages.

• In these messages, %1 stands for the device type (KSP).
• In these messages, %2 stands for the number of the drive or power
supply (KSP).
• %3 stands for error codes for further differentiation of the cause of the
error.

Error no. Warning Cause Remedy

26103 Internal error, The device has detec- • Reinitialize the drive bus:
KSP (axis) ted an internal error. Power Off / Power On
26104 IxT overload Axis overloaded • During start-up => excessive
error, KSP (axis) Mean continuous cur- load in program
rent too high • Reinitialize the drive bus:
Power or load too high Power Off / Power On
• During operation
‒ Modifications to system
‒ Check machine
‒ Temperature influences
• Check trace recording of ax-
is/current
• Adapt program velocity
• Check CBS pressure
• Check gear unit
26105 Ground fault, KSP Power unit overcurrent • Check motor cable
(axis) (ground fault)
• Check motor
• Reinitialize the drive bus:
Power Off / Power On
26106 Overcurrent, KSP Fault that briefly re- • Check trace recording of ax-
(axis) sults in an overcurrent is/current
that exceeds the maxi-
• Check motor
mum current of the
KSP (short-circuit,…) • Check motor cable
• Reinitialize the drive bus:
Power Off / Power On
26107 Intermediate cir- Overvoltage in inter- • Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
high, KSP (axis) operation
• Check mains voltage
• Check brake resistor (inter-
ruption)
• Excessive load during brak-
ing => reduce
• Reinitialize the drive bus:
Power Off / Power On

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Error no. Warning Cause Remedy

26108 Intermediate cir- Undervoltage in inter- • Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
low, KSP (axis) operation
• Check mains voltage
• Reinitialize the drive bus:
Power Off / Power On
26111 Device tempera- Overtemperature • Check the fans
ture too high,
• Check ambient temperature
KSP (axis)
• Load in program too high,
check load
• Dirt in cooling circuit =>
clean
• Reinitialize the drive bus:
Power Off / Power On
26112 Heat sink temper- Overtemperature of • Check the fans
ature too high, heat sink
• Check ambient temperature
KSP (axis)
• Load in program too high,
check and reduce load
• Dirt in cooling circuit =>
clean
• Check installation site, venti-
lation slits and clearance
• Reinitialize the drive bus:
Power Off / Power On
26113 Motor phase fail- Failure of motor phase • Check motor cable
ure, KSP (axis)
• Check motor
• Reinitialize the drive bus:
Power Off / Power On
26114 Communication Communication error • Reinitialize the drive bus:
error, KSP (axis) on the controller bus Power Off / Power On
• Check EtherCAT cabling
• Check EtherCAT stack
26117 Hardware fault, The device has detec- • Reinitialize the drive bus:
KSP (axis) ted an internal hard- Power Off / Power On
ware fault.
26118 Mains phase fail- Failure of mains phase • Check power lead
ure, KSP (axis)
• Reinitialize the drive bus:
Power Off / Power On
26119 Power supply fail- Supply voltage failure • Check power lead
ure, KSP (axis)
26122 Fault in brake re- KSP has detected an • Check brake resistor
sistor, KSP (axis) error
26123 Overload of brake Braking energy perma- • Reduce heavy loads that are
resistor, KSP (ax- nently too high braked too frequently
is)
• Check brake resistor
• Reinitialize the drive bus:
Power Off / Power On

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Troubleshooting
Error no. Warning Cause Remedy
26131 Intermediate cir- - • Check intermediate circuit ca-
cuit charging bling
failed, KSP (axis)
• Reinitialize the drive bus:
Power Off / Power On
• Check mains connection
• Check system impedance
26133 Group brake fault, Brake cable monitoring • Check motor / brake (meas-
KSP (axis) device has signaled ure)
short-circuit, overload-
• Check brake cable / motor
ing or break in connec-
cable
tion. / short-circuit /
overcurrent / no brake • Reinitialize the drive bus:
connected Power Off / Power On

11.2 Controller System Panel LED display

Overview

Fig. 11-1: Controller System Panel LED arrangement

Item Element Color Meaning

1 LED1 White Operating mode LED (Test or
Automatic)
2 LED2 Green Operating status LED
3 LED3 Red Error LED
4 LED4 “soft White Sleep LED
power” button

Controller state

Display Description State

LED1...LED4 = off Controller is off

LED1...LED3 = off Controller is in Sleep

mode (standby mode)
LED4 flashes irregu-
larly
LED1...LED3 = off Controller is in Bus
Power Off mode
LED4 flashes slowly
(regularly)

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Switching on the controller

Display Description State

LED1…LED4 = on LED test being per-
formed (duration min.
2 s)
LED1…LED4 = off BIOS post test still
running
LED test is completed
LED2 flashes slowly BIOS OK
(regularly)
Starting booting of
LED1, LED 3 and controller
LED4 = off
LED1 = on or off, de- Booting completed
pending on the last successfully
state
LED2 = on

Controller in operation

Display Description State

LED2 = on Controller is running in
T1 or T2 mode
LED1 = on Controller is running in
Automatic mode
LED2 = on

ProfiNet ping

Display Description State

LED1 = on or off, de- ProfiNet ping is being
pending on the last executed
state
LED2 = on
LED3 = flashes quick-
ly

Maintenance

Display Description State

LED1 = on or off, de- Maintenance mode ac-
pending on the last tive (robot controller
state maintenance due)
LED2 = on
LED3 = flashes slowly
(regularly)

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Troubleshooting
Controller is shutting down

Display Description State

LED1 = on or off, de- Controller not yet
pending on the last shutting down
state
LED2 = on
(Device switch/main
switch off or power
failure)
LED2 = on Controller shutting
down
(Device switch/main
switch off, power fail-
ure or soft power
down)
LED4 = flashes irregu- Controller has been
larly shut down

11.3 Controller System Panel LED error display

Error on switching on

Display Description Remedy

LED2 = flashes quick- • Swap the SSD
ly with an SSD from
LED3 = on another robot con-
troller
BIOS error has occur-
• Check the USB
red
stick

Error when booting

Display Description Remedy

LED2 = flashes slowly Reload the image
LED3 = on
Timeout on starting
the PMS
LED2 = flashes quick- Reload the image
ly
LED3 = flashes quick-
ly
Software boot error

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Error during operation

Display Description Remedy

LED1 = on or off, de- Check error messages
pending on the last on the smartPAD
state
LED2 = on
LED3 = on
Fatal error

11.4 Creating or restoring a KR C5 recovery image

Description

The complete image can be created and, if necessary, reloaded using the
KUKA Recovery Tool. The image can be created and/or loaded in Auto-
matic mode.
The creation or restoration of the image is described in the following sec-
tion.

Equipment

The following equipment is required:

Designation Article number
KUKA.Recovery USB stick in version V.4 KUKA.Recovery USB Stick
or higher 4.0
PC/laptop with Windows 10, 64-bit -

Precondition

• The robot controller is switched off.

Overview

Fig. 11-2: Controller System Panel LED arrangement

Item Element Color Meaning

1 LED1 White Operating mode LED (Test or
Automatic)
2 LED2 Green Operating status LED
3 LED3 Red Error LED
4 LED4 “soft White Sleep LED
power” button

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Troubleshooting
11.4.1 Creating a recovery image

Procedure

1. Connect the KUKA.Recovery USB stick to the robot controller.

2. Switch on the robot controller.
The states are displayed on the CSP in the following order:

Creating an image in automatic mode

Display Description State

LED2 flashes regularly Robot controller is
booting.
LED2 = on Boot operation has
been completed.
LED2 = on Image of the C:\ parti-
tion is being created.
LED4 flashes regularly
LED2 = on Image creation of the
C:\ partition has been
LED4 = on
completed.
LED1 flashes regularly Image of the D:\ parti-
tion is being created.
LED2 = on
LED4 = on
LED1 = on Image creation of the
D:\ partition has been
LED2 = on
completed.
LED4 = on
LED2…LED4 = on A complete image has
been created. All
LEDs light up for 1 s.
LED2 flashes slowly Controller is shutting
(regularly) down
LED4 flashes irregu- Controller has been
larly shut down

Error

Display Description State

LED1 and LED4 retain An error occurred dur-
the most recently dis- ing restoration of the
played state image.
LED2 and LED3 = on Remedy:

• Check SSD
• Check the USB
stick
• Reload the image

11.4.2 Restoring a recovery image

Procedure

1. Connect the KUKA.Recovery USB stick to the robot controller.

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2. Switch on the robot controller.

The states are displayed on the CSP in the following order:

Restoring an image in automatic mode

Display Description State

LED2 flashes regularly Robot controller is
booting.
LED2 = on Boot operation has
been completed.
LED2 = on Image of the C:\ parti-
tion is being restored
LED4 flashes regularly
and copied to the hid-
den partition.
LED2 = on Restoration of the C:\
partition has been
LED4 = on
completed.
LED1 flashes regularly Image of the D:\ parti-
tion is being restored
LED2 = on
and copied to the hid-
LED4 = on den partition.
LED1 = on Image creation of the
D:\ partition has been
LED2 = on
completed.
LED4 = on
LED2…LED4 = on A complete image has
been restored. All
LEDs light up for 1 s.
LED2 flashes slowly Controller is shutting
(regularly) down
LED4 flashes irregu- Controller has been
larly shut down

Error

Display Description State

LED1 and LED4 retain An error occurred dur-
the most recently dis- ing restoration of the
played state image.
LED2 and LED3 = on Remedy:

• Check SSD
• Check the USB
stick
• Reload the image

11.4.3 Terminating KUKA.Recovery

Procedure

1. Switch the robot controller off.

2. Remove the KUKA.Recovery USB stick.

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Troubleshooting
11.4.4 Concluding work

Once the image has been created or restored, the following tasks must be
carried out:

Procedure

1. Switch on the robot controller and check the settings.

2. Carry out a function test.

11.5 System board LED fault indicator

Description

There are LEDs on the system boards which light up red in the event of a
fault. The light can be seen through the openings at the air inlet of the
cooling system.

Fig. 11-3: Front view

1 “Basic” system board 2 “Performance” system board

Procedure

1. Switch off the robot controller.

2. Disconnect the power cable. Store the disconnected power cable out
of sight and reach of the robot controller.
3. Contact KUKA Customer Support.

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Decommissioning, storage and disposal

12 Decommissioning, storage and disposal

12.1 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
decommissioning, it is prepared for storage or for transportation to a differ-
ent location.

Equipment

The following equipment is required:

Designation Article number
TORX screwdriver set TX10 -

Precondition

• The removal site is freely accessible.

• There is no hazard posed by system components.
• The robot controller is switched off at the device switch and the mains
connection is disconnected.

Work safety

Work on the electrical and mechanical equipment of the machine may

only be carried out by specially trained personnel.

Procedure

1. Release and unplug all peripheral connections.

2. Release and unplug the motor cable and control cable connectors.
3. Release and unplug the ground conductor.
4. Prepare the robot controller for storage.

12.1.1 Concluding work

The following concluding work must be carried out:

• Prepare individual components for storage (>>> 12.2 "Storage"
Page 133) or dispose of them in accordance with the pertinent regula-
tions (>>> 12.3 "Disposal" Page 134).

12.2 Storage

Description

The robot controller can be stored fully assembled.

Storage location

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.

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• Avoid wind and drafts.

• Avoid condensation.
• Observe and comply with the permissible temperature ranges for stor-
age.
• Select a storage location in which the packaging film cannot be dam-
aged.
• Only store the robot controller indoors.

Procedure

1. Clean the robot controller. No dirt may remain on or in the robot con-
troller.
2. Inspect the robot controller, both internally and externally, for damage.
3. Remove batteries and store in accordance with the manufacturer’s in-
structions.
4. Remove any foreign bodies.
5. Remove any corrosion expertly.
6. Attach all covers to the robot controller and check that the seals are
correctly 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.

12.3 Disposal

When the robot controller reaches the end of its useful life, it can be dis-
mantled, and the materials can be disposed of properly by type.
The following table provides an overview of the materials used in the ro-
bot controller. Some of the plastic components are marked with a material
designation and must be disposed of accordingly.
As the end user, the customer is legally required to return depleted bat-
teries. Used batteries can be returned to the vendor or brought to the
designated collection points (e.g. in communal refuse collection facilities
or commercial centers) free of charge. The batteries can also be sent to
the vendor by post.
The following symbols can be found on the batteries:
• Crossed-out garbage can: battery must not be disposed of with ordi-
nary household refuse.

• Pb: battery contains more than 0.004 lead by weight.

• Cd: battery contains more than 0.002 cadmium by weight.
• Hg: battery contains more than 0.0005 mercury by weight.

Material Subassembly, component Additional information

Metals
Aluminum Housing cover and heat
sink of the robot controller
CuZn Connectors, contacts Dispose of without disman-
(gold-plated) tling
Copper Electrical cables, wires
Steel Screws, washers, plates

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Decommissioning, storage and disposal

Material Subassembly, component Additional information
Steel Screws, washers
(ST 52-3)
Electrical parts
Electronic components, Dispose of as electrical
such as RDC, EDS, circuit scrap without disassem-
board bling
Plastics
EPDM Seals, covers
ETFE Flexible tube
NBR O-rings
PE Cable straps
PUR Cable sheaths

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Appendix
13 Appendix

13.1 Applied standards and regulations

Name/Edition Definition

2006/42/EC:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)

2014/30/EU:2014 EMC Directive:

Directive 2014/30/EC of the European Parliament and of the Coun-
cil dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility

EN 55011:2009 + Industrial, scientific and medical equipment:

A1:2010
Radio disturbance characteristics – Limits and methods of measure-
ment

EN 60204-1:2018 Safety of machinery:

Electrical equipment of machines – Part 1: General requirements

EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments

EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments

EN 61010-2-201:2013 + Safety requirements for electrical equipment for measurement,

AC:2013 control and laboratory use
Part 2-201: Particular requirements for control equipment

EN 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles

EN 62061:2005 + Safety of machinery:

A1:2013 + A2:2015
Functional safety of safety-related electrical, electronic and pro-
grammable electronic control systems

EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1

EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction

EN ISO 13849-1:2015 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles
of design

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EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation

EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

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KUKA Service
14 KUKA Service

14.1 Requesting support

Introduction

This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.

Information

The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used

14.2 KUKA Customer Support

The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

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Index Data cables XF21, connecting.......................91

Declaration of conformity............................... 17
2006/42/EC:2006.......................................... 137
Declaration of incorporation.....................17, 18
2014/30/EU:2014.......................................... 137
Decommissioning................................... 46, 133
95/16/EC....................................................... 137
Description....................................114, 116, 120
Components, industrial robot.................... 11
Device connection cable................................ 13
A Dimensions
Accessories.....................................................17 Robot controller......................................... 51
ANSI/RIA R.15.06-2012............................... 137 Disposal......................................... 46, 133, 134
Appendix....................................................... 137 Documentation, industrial robot....................... 7
Applied standards and regulations.............. 137 Drive box........................................................ 13
Automatic External (operating mode)............ 26 Dynamic testing.............................................. 83
Automatic mode..............................................44
Axis limitation, mechanical............................. 32
Axis range.......................................................18
E
EC declaration of conformity......................... 17
EDS...................................................................8
B EDS cool...........................................................8
Br M.................................................................. 8 Electromagnetic compatibility (EMC)........... 137
Brake defect................................................... 35 Electromagnetic compatibility (EMC):.......... 137
Brake release device......................................33 Electromagnetic compatibility, EMC...............57
Braking distance............................................. 18 EMC.................................................................. 8
EMC Directive........................................ 18, 137
EMD.................................................................. 8
C EMERGENCY STOP device...... 28, 29, 34, 35
CE mark..........................................................18 EMERGENCY STOP, external................ 29, 39
CK, monitoring................................................31 EMERGENCY STOP, local............................ 39
Cleaning work.................................................45 EN 55011:2009 + A1:2010.......................... 137
Components EN 60204-1:2018......................................... 137
Accessories................................................11 EN 61000-6-2:2005...................................... 137
Connecting cables..................................... 11 EN 61000-6-4:2007 + A1:2011.................... 137
Manipulator................................................ 11 EN 61010-2-201:2013 + AC:2013............... 137
Options.......................................................11 EN 614-1:2006+A1:2009..............................137
Robot controller......................................... 11 EN 62061:2005 + A1:2013 + A2:2015........137
Software..................................................... 11 EN ISO 10218-1:2011.................................. 137
Teach pendant........................................... 11 EN ISO 12100:2010..................................... 137
Connecting cables.......................................... 17 EN ISO 13849-1:2015..................................137
Connecting...............................................100 EN ISO 13849-2:2012..................................138
Routing.......................................................66 EN ISO 13850:2015..................................... 138
Connection conditions.................................... 65 Enabling device................................. 29, 34, 35
Connection panel............................................11 Enabling device, external............................... 31
Control box Enabling switch, external............................... 79
“Basic” system board................................ 12 Enabling switches...........................................29
Control unit..................................................... 11 Equipment..................................................... 116
Controller System Panel................................ 14 Ethernet interface............................................. 8
LED display............................................. 125 KLI IT.........................................................73
LED error display.................................... 127 KSI............................................................. 72
Counterbalancing system............................... 45 EtherNet/IP....................................................... 8
CSP.................................................................14 EXT (operating mode)....................................26
LED display............................................. 125 External axes..................................................17
LED error display.................................... 127 External axis................................................... 20
External axis enabling switch
Function..................................................... 80
D
Daisy chain....................................................... 8
Daisy chain interface F
XF3............................................................ 73 Fast Measurement inputs...............................90
XF4............................................................ 73 Faults.............................................................. 36
Danger zone................................................... 19 Function test................................................... 38

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Fuse KUKA smartPAD.............................................19

Exchanging.............................................. 120 KUKA smartPAD-2..................................... 9, 19
Fusing............................................................. 67

L
G Labeling.......................................................... 33
General safety measures............................... 35 Liability............................................................ 17
Ground conductor Linear unit.......................................................17
Connecting...............................................100 Low-side mode............................................... 75
Low Voltage Directive.....................................18

H
Hazardous substances................................... 46 M
High-side mode.............................................. 75 M....................................................................... 9
HMI................................................................... 9 Machine data.................................................. 39
Machinery Directive................................18, 137
Mains power supply, connecting..................101
I Maintenance........................................... 44, 107
IFBstd................................................................9 Maintenance symbols...................................107
Industrial robot................................................17 Manipulator.......................................... 9, 17, 19
Infeed.............................................................. 67 Manual mode..................................................43
Inputs, Fast Measurement............................. 89 Material.........................................115, 116, 120
Installation conditions..................................... 58 Material designation..................................... 134
Intended use...................................................15 Maximum cable length.. 71–74, 76, 78, 82, 90,
Interface 92
KLI 1.......................................................... 73 Mechanical end stops.................................... 32
KLI 2.......................................................... 73 mini CSP...........................................................9
Daisy chain................................................73 Minimum clearances, robot controller............51
KEI............................................................. 73 Misuse.............................................................15
KLI IT.........................................................73 Monitoring, physical safeguards.............. 27, 28
KONI.......................................................... 72 Monitoring, velocity.........................................31
KSI Ethernet.............................................. 72 Motherboard battery, exchanging.................116
USB............................................................71 Motor cable, data cable................................. 13
XGDP.........................................................74 Motor interface
Introduction....................................................... 7 XD20.1....................................................... 92
IT security....................................................... 36 XD20.2....................................................... 92

J N
Jog mode...........................................31, 34, 35 NA..................................................................... 9

K O
KCB...................................................................9 Operating mode selection........................ 24–26
KEB...................................................................9 Operation...................................................... 105
KEI..............................................................9, 73 Operator safety..................... 24, 27, 28, 34, 35
KLI.....................................................................9 Operators........................................................ 21
XF5............................................................ 73 Options............................................................17
XF6............................................................ 73 Overload......................................................... 35
KONI Overview
Interface..................................................... 72 Start-up...................................................... 97
KRL................................................................... 9 Overview of planning......................................57
KSB...................................................................9
KSI..............................................................9, 72
KSP...................................................................9 P
KSP warning messages............................... 123 Panic position................................................. 30
KSS............................................................ 9, 19 PE, equipotential bonding.............................. 64
KUKA Customer Support............................. 139 PELV................................................................. 9
KUKA Service...............................................139 PELV power supply unit....................75, 76, 78

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Performance level...........................................93 Safety measures.............................................35

Performance Level......................................... 24 Safety of machinery.............................137, 138
Peripheral cables............................................13 Safety options.................................................19
Peripheral contactor....................................... 42 Safety STOP 0............................................... 19
Personal protective equipment...................... 21 Safety STOP 1............................................... 19
Personnel........................................................20 Safety STOP 2............................................... 19
PFH values..................................................... 93 Safety STOP 0............................................... 19
PL....................................................................93 Safety STOP 1............................................... 19
Planning.......................................................... 57 Safety STOP 2............................................... 19
Planning, overview......................................... 57 Safety zone.............................................. 19, 22
Plant integrator............................................... 20 Safety, general................................................17
Plates and labels............................................53 SD card...........................................................71
PLC................................................................. 10 Service life...................................................... 18
PoE................................................................... 9 Simulation....................................................... 44
Positioner........................................................ 17 Single point of control.................................... 46
Power cutoff....................................................77 SION................................................................. 9
Power failure...................................................77 smartPAD........................................... 10, 20, 36
Power supply Plugging in...............................................101
Fast Measurement.................................... 90 smartPAD-2.....................................................20
Power supply connection smartPAD cable..............................................13
XD1............................................................ 67 Soft power button......................................... 105
Power unit.......................................................11 Software..........................................................17
Pressure Equipment Directive........................45 Software limit switches......................32, 34, 35
Preventive maintenance work........................ 45 SOP................................................................ 10
Product description......................................... 11 Spare parts...........................................116, 121
Protective equipment......................................31 SPOC..............................................................46
PSA.................................................................21 SSD.................................................................10
Exchanging.............................................. 114
Start-up.....................................................37, 97
Q Overview.................................................... 97
QBS.................................................................. 9 Start-up mode.................................................41
STOP 0.................................................... 18, 20
STOP 1.................................................... 18, 20
STOP 2.................................................... 18, 20
R Stop category 0.............................................. 20
RDC.................................................................. 9
Stop category 1.............................................. 20
RDC cool.......................................................... 9
Stop category 2.............................................. 20
Reaction distance........................................... 18
Stop category 1, Drive Ramp Stop............... 20
Recommissioning..................................... 37, 97
Stop reactions.......................................... 22, 23
Release device............................................... 33
STOP 1 - DRS............................................... 20
Repair..................................................... 44, 111
Stopping distance.................................... 18, 22
Robot controller........................................ 11, 17
Storage................................................... 46, 133
Installing.....................................................99
Support request............................................ 139
Robot controller stacked................................ 59
System board................................................. 10
Robot controller, switching on............. 102, 105
System integrator.............................. 18, 20, 21

S T
Safe input....................................................... 82
T1 (operating mode)................................ 20, 26
Safe operational stop..................................... 19
T2 (operating mode)................................ 20, 26
Safe output..................................................... 84
Target group..................................................... 7
Safeguards, external...................................... 34
Teach pendant................................................ 17
Safely isolated................................... 75, 76, 78
Technical data.................................................49
Safety..............................................................17
Terms
Safety controller..............................................24
Used.............................................................8
Safety functions........................................24, 34
Terms used....................................................... 8
Safety functions, Ethernet safety interface....85
Terms, safety.................................................. 18
Safety functions, overview............................. 24
Trademarks....................................................... 8
Safety instructions............................................ 7
Training............................................................. 7
Safety interfaces.............................................13
Transportation.......................................... 37, 95
Safety logic..................................................... 11

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Troubleshooting............................................ 123
Turn-tilt table...................................................17

U
UPS.......................................................... 10, 77
UPS, battery box............................................ 13
UPS, connecting...........................................101
US1................................................................. 10
US2...........................................................10, 42
USB.................................................................10
Interface..................................................... 71
User.......................................................... 18, 21

V
Velocity monitoring......................................... 31
Vibration resistance........................................ 50
VSS.................................................................20

W
Warnings........................................................... 7
Work safety................................................... 116
Workspace................................................18, 22

X
XD1
Power supply connection.......................... 67
XD20.1
Motor interface.......................................... 92
XD20.2
Motor interface.......................................... 92
XF1 - XF8
Interface..................................................... 71
XG11.1
Configuring...............................................102
XG33
Inputs, Fast Measurement........................ 89
XG58
Configuring...............................................102
XGDP..............................................................74
XGSD
Interface..................................................... 71
SD card..................................................... 71

144/144 | www.kuka.com MA KR C5 micro V3 | Issued: 21.09.2020