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Controller

KR C4 extended
ready2_rivet
Operating Instructions

Issued: 21.06.2018
BA KR C4 extended ready2_rivet V1
KUKA Deutschland GmbH
KR C4 extended

© Copyright 2018
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 BA KR C4 extended ready2_rivet (PDF) en


PB10846

Book structure: BA KR C4 extended ready2_rivet V1.1


BS10006

Version: BA KR C4 extended ready2_rivet V1

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KR C4 extended

Contents

1 Introduction.............................................................................................. 8
1.1 Industrial robot documentation.............................................................................. 8
1.2 Representation of warnings and notes................................................................. 8
1.3 Terms used............................................................................................................ 9
1.4 Trademarks............................................................................................................ 11

2 Purpose..................................................................................................... 12
2.1 Target group.......................................................................................................... 12
2.2 Intended use.......................................................................................................... 12

3 Product description................................................................................. 13
3.1 Overview of the robot controller........................................................................... 13
3.2 KUKA Power Pack................................................................................................ 14
3.3 KUKA Servo Pack................................................................................................. 15
3.4 Control PC............................................................................................................. 15
3.5 Cabinet Control Unit.............................................................................................. 16
3.6 Resolver Digital Converter.................................................................................... 17
3.7 Controller System Panel....................................................................................... 17
3.8 Low-voltage power supply..................................................................................... 18
3.9 Batteries................................................................................................................. 18
3.10 Mains filter............................................................................................................. 18
3.11 Bus devices........................................................................................................... 19
3.11.1 KCB devices.......................................................................................................... 19
3.11.2 KSB devices and configuration variants............................................................... 20
3.11.3 KEB devices and configuration variants............................................................... 20
3.12 Connection panel interfaces.................................................................................. 20
3.13 Motherboard D3445-K interfaces.......................................................................... 22
3.14 KUKA smartPAD holder (optional)........................................................................ 23
3.15 Cabinet cooling...................................................................................................... 24
3.16 Additional components.......................................................................................... 25

4 Technical data.......................................................................................... 26
4.1 Dimensions of robot controller.............................................................................. 28
4.2 Minimum clearances, robot controller................................................................... 29
4.3 Swing range for cabinet door............................................................................... 29
4.4 Dimensions of the smartPAD holder (optional).................................................... 30
4.5 Dimensions of boreholes for floor mounting........................................................ 30
4.6 Dimensions of boreholes for technology cabinet................................................. 31
4.7 Plates and labels................................................................................................... 31
4.8 REACH duty to communicate information acc. to Art. 33 of Regulation (EC)
1907/2006.............................................................................................................. 34

5 Safety......................................................................................................... 35
5.1 General.................................................................................................................. 35
5.1.1 Liability................................................................................................................... 35
5.1.2 Intended use of the industrial robot...................................................................... 35
5.1.3 EC declaration of conformity and declaration of incorporation............................ 36

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5.1.4 Terms used............................................................................................................ 36


5.2 Personnel............................................................................................................... 38
5.3 Workspace, safety zone and danger zone........................................................... 40
5.3.1 Determining stopping distances............................................................................ 40
5.4 Triggers for stop reactions.................................................................................... 40
5.5 Safety functions..................................................................................................... 41
5.5.1 Overview of the safety functions.......................................................................... 41
5.5.2 Safety controller..................................................................................................... 42
5.5.3 Selecting the operating mode............................................................................... 42
5.5.4 “Operator safety” signal......................................................................................... 43
5.5.5 EMERGENCY STOP device................................................................................. 44
5.5.6 Logging off from the higher-level safety controller............................................... 44
5.5.7 External EMERGENCY STOP device.................................................................. 45
5.5.8 Enabling device..................................................................................................... 45
5.5.9 External enabling device....................................................................................... 46
5.5.10 External safe operational stop.............................................................................. 46
5.5.11 External safety stop 1 and external safety stop 2............................................... 46
5.5.12 Velocity monitoring in T1....................................................................................... 46
5.6 Additional protective equipment............................................................................ 46
5.6.1 Jog mode............................................................................................................... 46
5.6.2 Software limit switches.......................................................................................... 46
5.6.3 Mechanical end stops........................................................................................... 47
5.6.4 Mechanical axis limitation (optional)..................................................................... 47
5.6.5 Options for moving the manipulator without drive energy................................... 47
5.6.6 Labeling on the industrial robot............................................................................ 48
5.6.7 External safeguards............................................................................................... 48
5.7 Overview of operating modes and safety functions............................................. 49
5.8 Safety measures.................................................................................................... 49
5.8.1 General safety measures...................................................................................... 49
5.8.2 Transportation........................................................................................................ 50
5.8.3 Start-up and recommissioning.............................................................................. 51
5.8.3.1 Checking machine data and safety configuration................................................ 52
5.8.3.2 Start-up mode........................................................................................................ 54
5.8.4 Manual mode......................................................................................................... 56
5.8.5 Simulation.............................................................................................................. 57
5.8.6 Automatic mode..................................................................................................... 57
5.8.7 Maintenance and repair........................................................................................ 57
5.8.8 Decommissioning, storage and disposal.............................................................. 59
5.8.9 Safety measures for “single point of control”....................................................... 59
5.9 Applied norms and regulations............................................................................. 60

6 Planning.................................................................................................... 62
6.1 Electromagnetic compatibility (EMC).................................................................... 62
6.2 Installation conditions............................................................................................ 63
6.3 Connection conditions........................................................................................... 64
6.4 Fastening the KUKA smartPAD holder (optional)................................................ 65
6.5 Overview of lower interfaces................................................................................. 66
6.5.1 Power supply connection via Harting connector X1............................................ 67
6.5.2 Motor interfaces..................................................................................................... 68

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6.5.2.1 Motor connector X20, KPP and KSP................................................................... 69


6.5.2.2 Motor connector X7.1, external axis 1................................................................. 70
6.5.3 Cable inlet X51...................................................................................................... 70
6.5.4 X56 load voltages US1/US2................................................................................. 70
6.5.5 X55 external power supply................................................................................... 71
6.5.6 X67.1, X67.2 and X67.3 KLI interfaces................................................................ 72
6.5.7 X65 EtherCAT interface........................................................................................ 73
6.5.8 X19 KUKA smartPAD............................................................................................ 74
6.5.9 X21 US2 RDC interface........................................................................................ 74
6.5.10 X42 reference switch............................................................................................. 75
6.6 Discrete interfaces for safety options................................................................... 76
6.6.1 Safety functions via Ethernet safety interface...................................................... 76
6.6.1.1 Schematic circuit diagram for enabling switches................................................. 80
6.6.1.2 SafeOperation via Ethernet safety interface (optional)........................................ 81
6.7 Overview of side interfaces................................................................................... 84
6.7.1 XS1EC, XS2EC, XS5EC: EtherCAT interfaces for Böllhoff peripheral equip-
ment....................................................................................................................... 85
6.7.2 XS1EP, XS2EP, XS5EP: 24 V DC supply for Böllhoff peripheral equipment...... 86
6.8 EtherCAT connection on the CIB......................................................................... 86
6.9 Motor box and RDC box connection examples................................................... 87
6.10 PE equipotential bonding...................................................................................... 87
6.11 Modifying the system configuration, exchanging devices.................................... 89
6.12 Operator safety acknowledgement....................................................................... 89
6.13 Performance level.................................................................................................. 89
6.13.1 PFH values of the safety functions...................................................................... 89

7 Transportation.......................................................................................... 92
7.1 Transportation using lifting tackle......................................................................... 92
7.2 Transportation by fork lift truck............................................................................. 93
7.3 Transportation by pallet truck................................................................................ 96

8 Start-up and recommissioning............................................................... 97


8.1 Start-up overview................................................................................................... 97
8.2 Installing the robot controller................................................................................. 97
8.3 Connecting the connecting cables........................................................................ 98
8.3.1 Connecting data cables X21................................................................................. 99
8.3.2 Plugging in the KUKA smartPAD.......................................................................... 99
8.4 Fastening the KUKA smartPAD holder (optional)................................................ 100
8.5 Connecting the PE equipotential bonding............................................................ 100
8.6 Power supply connection via X1 Harting connector............................................ 100
8.7 Reversing the battery discharge protection measures......................................... 101
8.8 Modifying the system configuration, exchanging devices.................................... 101
8.9 Start-up mode........................................................................................................ 102
8.10 Switching on the robot controller.......................................................................... 103

9 Operation.................................................................................................. 104
9.1 KUKA smartPAD teach pendant........................................................................... 104
9.1.1 Front view.............................................................................................................. 104
9.1.2 Rear view............................................................................................................... 106

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10 Maintenance.............................................................................................. 108
10.1 Maintenance symbols............................................................................................ 108
10.2 Cleaning the robot controller................................................................................. 110

11 Repair........................................................................................................ 111
11.1 Repair and procurement of spare parts............................................................... 111
11.2 Exchanging the external fan................................................................................. 111
11.3 Exchanging the internal fan.................................................................................. 113
11.4 Exchanging control PC components..................................................................... 114
11.4.1 Exchanging the control PC................................................................................... 114
11.4.2 Exchanging the control PC fan............................................................................. 115
11.4.3 Exchanging the motherboard................................................................................ 117
11.4.4 Exchanging the motherboard battery.................................................................... 117
11.4.5 Exchanging the LAN Dual NIC network card....................................................... 117
11.4.6 Exchanging the hard drive.................................................................................... 118
11.5 Modifying the system configuration, exchanging devices.................................... 119
11.5.1 Exchanging the KUKA Power Pack...................................................................... 119
11.5.2 Exchanging the KUKA Servo Pack...................................................................... 122
11.5.3 Exchanging the Cabinet Control Unit................................................................... 125
11.5.4 Exchanging the Resolver Digital Converter.......................................................... 128
11.6 Exchanging the batteries in the cabinet door...................................................... 131
11.7 Exchanging the low-voltage power supply unit.................................................... 132
11.8 Exchanging the pressure relief plug..................................................................... 133
11.9 Exchanging the mains filter................................................................................... 134
11.10 Exchanging the KEB inverter................................................................................ 136
11.11 Exchanging the KEB mains filter.......................................................................... 137
11.12 Exchanging the KEB brake resistor...................................................................... 138
11.13 Installing the KUKA System Software (KSS) ...................................................... 139

12 Troubleshooting....................................................................................... 140
12.1 Cabinet Control Unit LED display......................................................................... 140
12.2 Cabinet Control Unit fusing................................................................................... 144
12.3 Resolver Digital Converter LED display............................................................... 145
12.4 Controller System Panel LED display.................................................................. 147
12.4.1 Controller System Panel LED error display......................................................... 149
12.5 LAN Onboard LED display on motherboard D3445-K......................................... 149
12.6 Checking the KUKA Servo Pack.......................................................................... 150
12.7 Checking the KUKA Power Pack 3...................................................................... 151
12.8 KPP and KSP error messages............................................................................. 152
12.9 KPP and KSP warning messages........................................................................ 156

13 Decommissioning, storage and disposal............................................. 160


13.1 Decommissioning................................................................................................... 160
13.2 Storage.................................................................................................................. 160
13.3 Disposal................................................................................................................. 161

14 KUKA Service........................................................................................... 162


14.1 Requesting support............................................................................................... 162
14.2 KUKA Customer Support...................................................................................... 162

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Index 170

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Introduction KR C4 extended

1 Introduction

1.1 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the manipulator


• Documentation for the robot controller
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.2 Representation of warnings and notes

Safety

These warnings are relevant to safety 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 pre-
cautions are taken.

These warnings contain references to safety-relevant information or


general 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.

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Introduction
1.3 Terms used

Term Description
Br M{Number} Brake Motor{Number}
CCU Cabinet Control Unit
CIB Cabinet Interface Board
CIP Safety Common Industrial Protocol Safety
CIP Safety is an Ethernet/IP-based safety in-
terface for connecting a safety PLC to the ro-
bot controller. (PLC = master, robot controller
= slave)
CK Customer-built Kinematics
CSP Controller System Panel
Display element and connection point for USB
and network
Dual NIC Dual Network Interface Card
Dual-port network card
EDS Electronic Data Storage (memory card)
EH Electro-hydraulic
EMD Electronic Mastering Device
EMC ElectroMagnetic Compatibility
Ethernet/IP Ethernet/Internet Protocol is an Ethernet-based
field bus.
HMI Human Machine Interface:
KUKA.HMI is the KUKA user interface.
KCB KUKA Controller Bus
KEB KUKA Extension Bus
KLI KUKA Line Interface
Connection to higher-level control
infrastructure (PLC, archiving)
KOI KUKA Operator Panel Interface
KONI KUKA Option Network Interface
Interface for KUKA options
KPC KUKA control PC
KPP KUKA Power Pack
Drive power supply with drive controller
KRL KUKA Robot Language
KUKA programming language
KSB KUKA System Bus
A field bus for internal networking of the con-
trollers
KSI KUKA Service Interface
Interface on the CSP on the control cabinet

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Introduction KR C4 extended

Term Description
The WorkVisual PC can either connect to the
robot controller via the KLI or it can be plug-
ged into the KSI.
KSP KUKA Servo Pack
Drive controller
KSS KUKA System Software
M{Number} Motor {Number}
Manipulator The robot arm and the associated electrical in-
stallations
NA North America
PELV Protective Extra Low Voltage
External 24 V power supply
QBS Operator safety acknowledgment signal
RDC Resolver Digital Converter (KR C4)
RTS Request To Send
Transmission request signal
SATA connections Data bus for exchanging data between the
processor and the hard drive
SG FC Servo gun
SIB Safety Interface Board
SION Safety I/O Node
SPRT Self-pierce riveting tool
SOP SafeOperation
Option with software and hardware compo-
nents
PLC A Programmable Logic Controller
is used in systems as a higher-level master
module in the bus system
SRM SafeRangeMonitoring
Safety option with software and hardware
components
SSB SafeSingleBrake
Safety option
US1 Load voltage (24 V) not switched
US2 Load voltage (24 V) switched. Deactivates ac-
tuators, for example, when the drives are de-
activated
USB Universal Serial Bus
Bus system for connecting additional devices
to a computer
EA External axis (linear unit, Posiflex)

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Introduction
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.

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Purpose KR C4 extended

2 Purpose

2.1 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 our products, we recommend that our customers


take part in a course of training at KUKA College. Information about the
training program can be found at www.kuka.com or can be obtained di-
rectly from our subsidiaries.

2.2 Intended use

Use

The robot controller is intended solely for operating the following compo-
nents:
• KUKA industrial robots
This controller contains the advanced function Control of the self-pierce
riveting tool via KEB inverter. Only the electro-hydraulic self-pierce rivet-
ing tools from Böllhoff can be moved using the advanced function. The
built-in Beckhoff PC with the corresponding software from Böllhoff takes
over the parameters and control functions.

Misuse

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


misuse and is not allowed. This includes e.g.:
• Use as a climbing aid
• Operation outside the permissible operating parameters
• Use in potentially explosive environments
• Use in underground mining

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Product description
3 Product description

3.1 Overview of the robot controller

The robot controller consists of the following components:

• Control PC (KPC)
• Low-voltage power supply
• Drive power supply with drive controller: KUKA Power Pack (KPP)
• Drive controller: KUKA Servo Pack (KSP)
• Teach pendant (KUKA smartPAD)
• Cabinet Control Unit (CCU)
• Controller System Panel (CSP)
• Fuse elements
• Batteries
• Fan
• Connection panel

Fig. 3-1: Overview of robot controller, front view

1 Main switch 9 Fuse element Q5/Q6


2 KEB inverter 10 Connection panel, power
supply, motor cables
3 BECKHOFF PC 11 Connection panel, control ca-
bles, communication
4 Terminal strip for Böllhoff 12 CSP
components
5 Safety relays 13 Batteries
6 Drive controller KSP T1 14 Control PC
7 Drive controller KPP G1 15 KUKA smartPAD
8 PROFINET switch

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Ethernet switch
Product description

EtherCat coupler

Fig. 3-2: Overview of robot controller, rear view

1 External fan 4 Heat exchanger


2 Low-voltage power supply 5 Mains filter
unit
3 Brake resistor

3.2 KUKA Power Pack

Description

The KUKA Power Pack (KPP) is the drive power supply and generates a
rectified intermediate circuit voltage from an AC power supply. This inter-
mediate circuit voltage is used to supply the internal drive controllers and
external drives. There are LEDs on the KPP which indicate the operating
state.
• KPP with amplifier for three axes (KPP 600-20-3x20)
Peak output current 3x20 A

Functions

The KPP has the following functions:


• KPP central AC power supply connection in interconnected operation
• Power output with 400 V supply voltage: 14 kW
• Rated current: 25 A DC
• Connection and disconnection of the supply voltage
• Powering of several axis amplifiers from the DC link

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Product description
• Integrated brake chopper through connection of an external ballast re-
sistor
• Overload monitoring by the ballast resistor
• Stopping of synchronous servomotors by means of short-circuit braking

3.3 KUKA Servo Pack

Description

The KUKA Servo Pack (KSP) is the drive controller for the manipulator
axes. There are LEDs on the KSP which indicate the operating state.
• KSP for 3 axes (KSP 600-3x40)
Peak output current 3x 40 A

Functions

The KSP has the following functions:


• Power range: 11 kW to 14 kW per axis amplifier
• Direct infeed of the DC intermediate circuit voltage
• Field-oriented control for servomotors: Torque control

3.4 Control PC

PC components

The control PC (KPC) includes the following components:


• Power supply unit (not present on all motherboard variants)
• Motherboard
• Processor
• Heat sink
• Memory modules
• Hard drive
• LAN Dual NIC network card (not present on all motherboard variants)
• PC fan
• Optional modules, e.g. field bus cards

Functions

The control PC (KPC) is responsible for the following functions of the ro-
bot controller:
• Graphical user interface
• Program creation, correction, archiving, and maintenance
• Sequence control
• Path planning
• Control of the drive circuit
• Monitoring
• Safety equipment
• Communication with external periphery (other controllers, host comput-
ers, PCs, network)

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Product description KR C4 extended

3.5 Cabinet Control Unit

Description

The Cabinet Control Unit (CCU) is the central power distributor and com-
munication interface for all components of the robot controller. The CCU
consists of the Cabinet Interface Board (CIB) and the Power Management
Board (PMB). All data are transferred via this internal communication inter-
face to the controller for further processing. If the mains voltage fails, the
control components continue to be powered by batteries until the position
data are saved and the controller has shut down. The charge and quality
of the batteries are checked by means of a load test.

Functions

• Communication interface for the components of the robot controller


• Safe inputs and outputs
‒ Control of main contactors 1 and 2
‒ Adjustment referencing (mastering test)
‒ KUKA smartPAD plugged in
• 4 Fast Measurement inputs for customer applications
• Monitoring of the fans in the robot controller
‒ Fans
‒ Control PC fan
• Temperature sensing:
‒ Thermostatic switch for transformer
‒ Alarm contact for cooling unit
‒ Alarm contact for main switch
‒ Temperature sensor for ballast resistor
‒ Temperature sensor for internal cabinet temperature
• The following components are connected to the KPC via the KUKA
Controller Bus:
‒ KPP/KSP
‒ Resolver Digital Converter
• The following operator panels and service devices are connected to
the control PC via the KUKA System Bus:
‒ KUKA Operator Panel Interface
• Diagnostic LEDs
• Electronic Data Storage Interface
Power supply with battery backup
• KPP
• KSP
• KUKA smartPAD
• Multi-core control PC
• Controller System Panel (CSP)
• Resolver Digital Converter (RDC)
Power supply without battery backup
• Motor brakes
• External fan
• Customer interface

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Product description
3.6 Resolver Digital Converter

Description

The Resolver Digital Converter (RDC) is used to detect the motor position
data. 8 resolvers can be connected to the RDC. In addition, the motor
temperatures are measured and evaluated. For non-volatile data storage,
the EDS is located in the RDC box.
The RDC is mounted in an RDC box on the base frame of the manipula-
tor.

Functions

The RDC has the following functions:


• Safe acquisition of up to 8 motor position data streams via resolver
• Detection of up to 8 motor operating temperatures
• Communication with the robot controller
• Monitoring of the resolver cables
• The following non-volatile data are stored on the EDS:
‒ Position data
‒ KUKA configuration

3.7 Controller System Panel

Description

The Controller System Panel (CSP) is a display element for the operating
state and has the following connections:
• USB1
• USB2
• KSI (optional)

Overview

Fig. 3-3: Arrangement of LEDs and connectors on CSP

Item Component Color Meaning


1 LED 1 Green Operating LED
2 LED 2 White Sleep LED
3 LED 3 White Automatic LED

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Item Component Color Meaning


4 USB 1 - -
5 USB 2 - -
6 RJ45 - KSI
7 LED 6 Red Error LED 3
8 LED 5 Red Error LED 2
9 LED 4 Red Error LED 1

3.8 Low-voltage power supply

Description

The low-voltage power supply unit provides power to the components of


the robot controller.
A green LED indicates the operating state of the low-voltage power supply
unit.

3.9 Batteries

Description

In the event of a power failure, or if the power is switched off, the batter-
ies enable the robot controller to be shut down in a controlled manner.
The batteries are charged via the CCU and the charge is checked and in-
dicated.

3.10 Mains filter

Description

The mains filter (interference suppressor filter) suppresses interference


voltages on the power cable.
Mains filters are installed for the following drive controllers:
• KSP drive controller
• KUKA drive controller

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Product description
3.11 Bus devices

Overview

Fig. 3-4: Overview of bus devices

1 KSP T1 8 KSI
2 KPP G1 9 CCU
3 Dual NIC card 10 KUKA Extension Bus (KEB)
4 CSP 11 KOI
5 Ethernet motherboard 12 RDC
6 KUKA Controller Bus (KCB) 13 Electronic Mastering Device
(EMD)
7 KUKA system bus (KSB) 14 KUKA smartPAD

3.11.1 KCB devices

KCB devices

The KCB includes the following devices:


• KPP
• KSP
• RDC
• CIB
• EMD

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3.11.2 KSB devices and configuration variants

KSB devices

The KSB includes the following devices:


• CIB SION
• smartPAD SION

3.11.3 KEB devices and configuration variants

KEB devices

The following components can be KEB devices:


• EtherCAT bridge master/master

3.12 Connection panel interfaces

Note

The following safety interfaces can be configured in the robot controller:


• Ethernet safety interface X67.1, X67.2 and X67.3
‒ PROFIsafe KLI

Overview

The connection panel of the robot controller consists of connections for


the following cables:
• Power cable / infeed
• Motor cables to the manipulator
• Data cables to the manipulator
• KUKA smartPAD cable
• PE cables
• Peripheral cables

Lower connection panel

Fig. 3-5: Connection panel overview

1 X1 power supply connection


2 Motor connector interfaces
3 X7.1 motor connector for external axis

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Product description
4 X51 cable inlet
5 X65 EtherCAT interface
6 X56 load voltages US1/US2
7 X67.1 PROFINET interface
8 X67.2 PROFINET interface
9 X19 smartPAD connection
10 X42 reference switch
11 X21 data cable
12 X67.3 PROFINET interface
13 X55 external power supplies
14 XP7.1 data interface, external axis
15 SL1 ground conductor to manipulator
16 SL2 ground conductor to main infeed

Side connection panel

Fig. 3-6: Connection panel overview

1 XS1EC: EtherCAT interface for Böllhoff peripheral equipment


2 XS2EC: EtherCAT interface for Böllhoff peripheral equipment
3 XS1EP: 24 V DC supply for Böllhoff peripheral equipment
4 XS2EP: 24 V DC supply for Böllhoff peripheral equipment
5 XS5EP: 24 V DC supply for Böllhoff peripheral equipment
6 XS5EC: EtherCAT interface for Böllhoff peripheral equipment

All contactor, relay and valve coils that are connected to the robot con-
troller by the user must be equipped with suitable suppressor diodes.
RC elements and VCR resistors are not suitable.

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Product description KR C4 extended

3.13 Motherboard D3445-K interfaces

Overview

Fig. 3-7: Motherboard D3445-K interfaces

1 Connector X961, power supply DC 24 V


2 Field bus cards, slots 1 to 7
3 LAN Onboard – KUKA Controller Bus
4 LAN Onboard – KUKA System Bus
5 2 USB 2.0 ports
6 2 USB 3.0 ports
7 DVI-D
8 Display port
9 4 USB 2.0 ports
10 LAN Onboard – KUKA Option Network Interface
11 LAN Onboard – KUKA Line Interface

VGA support is possible via DP on VGA adapter. The user interface of


the controller can only be displayed on an external monitor if no active
operator control device (smartPAD, VRP) is connected to the controller.

KUKA Deutschland GmbH has assembled, tested and supplied the


motherboard with an optimum configuration. No liability will be accepted
for modifications to the configuration that have not been carried out by
KUKA Deutschland GmbH.

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Product description
Slot assignment

Fig. 3-8: Slot assignment, motherboard D3445-K

Slot Type Plug-in card


1 PCI Field bus
2 PCI Field bus
3 - not available
4 - not available
5 PCIe Not assigned
6 - not available
7 - not available

3.14 KUKA smartPAD holder (optional)

Description

The optional KUKA smartPAD holder can be used to hang up the smart-
PAD and its connecting cable on the door of the robot controller or on the
safety fence.

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Product description KR C4 extended

Overview

Fig. 3-9: KUKA smartPAD holder

1 KUKA smartPAD holder 3 Front view


2 Side view

3.15 Cabinet cooling

Description

The control cabinet is divided into two cooling circuits. The inner zone,
containing the control and power electronics, is cooled by a heat exchang-
er. In the outer zone, the ballast resistor and the heat sinks of the KPP
and KSP are cooled directly by ambient air.
NOTICE
Upstream installation of filter mats at the ventilation slits causes an in-
crease in temperature, leading to a reduction in the service life of the
installed devices!

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Product description
Configuration

Fig. 3-10: Cooling circuits

1 Air inlet, external fan


2 Heat sink, low-voltage power supply
3 Air outlet, KPP/brake resistor
4 Air outlet, KSP/brake resistor
5 Air outlet, KSP/brake resistor
6 Air outlet for heat exchanger
7 Air outlet for mains filter
8 Internal fan
9 PC fan
10 KPC internal fan
11 Heat exchanger

3.16 Additional components

The following components are purchased parts:


• KEB inverter
• BECKHOFF PC
• Safety relays
Information about these components can be found in the corresponding
documentation.

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Technical data KR C4 extended

4 Technical data
Basic data

Cabinet type KR C4 extended


Number of axes max. 16
Weight 179 kg
Protection rating IP 54
Sound level according to Average: 65 dB (A)
DIN 45635-1
Installation with other cabinets Side-by-side, clearance 50 mm
(with/without cooling unit)
Load on cabinet roof with even 1,500 N
distribution

Power supply connection

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


supply systems.
Rated supply voltage, optionally: 3x380 V AC, 3x400 V AC
Permissible tolerance of rated Rated supply voltage ±10%
supply voltage
Mains frequency 49 ... 61 Hz
System impedance up to the con- ≤ 300 mΩ
nection point of the robot control-
ler
Ground leakage current with KPP up to 300 mA
G1
Ground leakage current with KPP up to 600 mA
G1 and G11
Short circuit current rating ≤480 V AC / 25 kA
575 V AC / 20 kA
Full-load current See rating plate
Mains-side fusing with KPP G1 min. 3x50 A, slow-blowing
and G11
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit.

Environmental conditions

Ambient temperature during oper- +5 ... 45 °C (278 ... 318 K)


ation without cooling unit
Ambient temperature during oper- +5 ... 50 °C (293 ... 323 K)
ation with cooling unit
Ambient temperature during stor- -25 ... +40 °C (248 ... 313 K)
age/transportation with batteries
Ambient temperature during stor- -25 ... +70 °C (248 ... 343 K)
age/transportation without batter-
ies

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Technical data
Temperature change max. 1.1 K/min
Humidity class 3k3 acc. to DIN EN 60721-3-3;
1995
Altitude • up to 1000 m above mean
sea level with no reduction in
power
• 1000 m ... 4000 m above
mean sea level with a reduc-
tion in power of 5%/1000 m

NOTICE
To prevent exhaustive discharge and thus destruction of the batteries,
the batteries must be recharged at regular intervals according to the
storage temperature.
If the storage temperature is +20 °C or lower, the batteries must be re-
charged every 9 months.
If the storage temperature is between +20 °C and +30 °C, the batteries
must be recharged every 6 months.
If the storage temperature is between +30 °C and +40 °C, the batteries
must be recharged every 3 months.

Vibration resistance

During trans- During continuous


Type of loading
portation operation
r.m.s. acceleration (sus- 0.37 g 0.1 g
tained oscillation)
Frequency range (sus- 4...120 Hz
tained oscillation)
Acceleration (shock in 10 g 2.5 g
X/Y/Z direction)
Waveform/duration (shock Half-sine/11 ms
in X/Y/Z direction)
If more severe mechanical stress is expected, the controller must be in-
stalled on anti-vibration components.

Control unit

Supply voltage DC 27.1 V ± 0.1 V

Control PC

Main processor See shipping version


DIMM memory modules See shipping version (min. 2 GB)
Hard drive See shipping version

KUKA smartPAD

Supply voltage 20 … 27.1 V DC


Dimensions (WxHxD) approx. 24x29x5 cm3
Display Touch-sensitive color display
600 x 800 pixels
Display size 8.4"
Interfaces USB

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Technical data KR C4 extended

Weight 1.1 kg
Protection rating (without USB IP 54
stick and USB connection closed
with a plug)

Cable lengths

For cable designations, standard lengths and optional lengths, please


refer to the operating instructions or assembly instructions of the manipu-
lator and/or the assembly and operating instructions for KR C4 external
cabling for robot controllers.
When using smartPAD cable extensions, only two extensions may be
used. An overall cable length of 50 m must not be exceeded.

The difference in the cable lengths between the individual channels of


the RDC box must not exceed 10 m.

4.1 Dimensions of robot controller

The dimensions of the robot controller are indicated in the diagram


(>>> Fig. 4-1).

Fig. 4-1: Dimensions

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Technical data
1 Front view
2 Side view
3 Top view

4.2 Minimum clearances, robot controller

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

Fig. 4-2: Minimum clearances

NOTICE
If the minimum clearances are not maintained, this can result in dam-
age to the robot controller. The specified minimum clearances must al-
ways be observed.

Certain maintenance and repair tasks on the robot controller


(>>> 10 "Maintenance" Page 108) (>>> 11 "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.

4.3 Swing range for cabinet door

The diagram (>>> Fig. 4-3) shows the swing range for the door.

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Technical data KR C4 extended

Fig. 4-3: Swing range for cabinet door

Swing range, standalone cabinet:


• Door with computer frame approx. 180°
Swing range, butt-mounted cabinets:
• Door approx. 155°

4.4 Dimensions of the smartPAD holder (optional)

The diagram (>>> Fig. 4-4) shows the dimensions and drilling locations
for mounting on the robot controller or safety fence.

Fig. 4-4: Dimensions and drilling locations for smartPAD holder

4.5 Dimensions of boreholes for floor mounting

The dimensions of the boreholes for floor mounting are indicated in the di-
agram (>>> Fig. 4-5).

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Technical data
Fig. 4-5: Boreholes for floor mounting

1 View from below

4.6 Dimensions of boreholes for technology cabinet

The diagram (>>> Fig. 4-6) shows the dimensions of the boreholes on the
KR C4 extended for fastening the technology cabinet.

Fig. 4-6: Fastening the technology cabinet

1 View from above

4.7 Plates and labels

Overview

The following plates and labels (>>> Fig. 4-7) are attached to the robot
controller. They must not be removed or rendered illegible. Illegible plates
and labels must be replaced.

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Technical data KR C4 extended

Fig. 4-7: Plates and labels

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

Item Description
1

Robot controller rating plate


2

Hot surface
During operation of the controller, surface temperatures may be
reached that could result in burn injuries. Protective gloves
must be worn!
3

Crushing hazard
Installation of the rear panel poses a crushing hazard. Protec-
tive gloves must be worn!

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Technical data
Item Description
4

KR C4 main switch
The main switch is connected to the robot.
5

Danger due to residual voltage


After the controller has been switched off, there is still a resid-
ual voltage in the intermediate circuit which is only discharged
some time later. The robot controller must be switched off and
discharged before any work is carried out on it.
≤ 780 VDC / wait 180 s
6

Electric shock hazard


The operating instructions and safety regulations must be read
and understood before work is carried out on the robot control-
ler.
7

Control PC rating plate

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Technical data KR C4 extended

Item Description
8

High leakage current

4.8 REACH duty to communicate information acc. to Art. 33 of Regulation


(EC) 1907/2006

On the basis of the information provided by our suppliers, the following


components of this product contain substances included on the Candidate
List of Substances of Very High Concern (SVHCs) in a concentration ex-
ceeding 0.1 percent by mass. None of these substances are released un-
der normal and reasonably foreseeable conditions of use.
Product REACH candidate/SVHC substance name CAS number
CR 2032 button cell 1,2-Dimethoxyethane; Ethylene glycol dimeth- 110-71-4
yl ether (EGDME)

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Safety
5 Safety

5.1 General

5.1.1 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 designated use and only by safety-conscious persons
who are fully aware of the risks involved in its operation. Use of the indus-
trial robot is subject to compliance with this document and with the decla-
ration of incorporation supplied together with the industrial robot. Any func-
tional disorders affecting safety must be rectified immediately.

Safety information

Information about safety may not be construed against KUKA Deutschland


GmbH. Even if all safety instructions are followed, this is not a guarantee
that the industrial robot will not cause personal injuries or material dam-
age.
No modifications may be carried out to the industrial robot without the au-
thorization of KUKA Deutschland GmbH. Additional components (tools,
software, etc.), not supplied by KUKA Deutschland GmbH, may be inte-
grated into the industrial robot. The user is liable for any damage these
components may cause to the industrial robot or to other material proper-
ty.
In addition to the Safety chapter, this document contains further safety in-
structions. These must also be observed.

5.1.2 Intended use of the industrial robot

The industrial robot is intended exclusively for the use designated in the
“Purpose” chapter of the operating instructions or assembly instructions.
Any use or application deviating from the intended use is deemed to be
misuse and is not allowed. The manufacturer is not liable for any damage
resulting from such misuse. The risk lies entirely with the user.
Operation of the industrial robot in accordance with its intended use also
requires compliance with the operating and assembly instructions for the

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KR C4 extended

individual components, with particular reference to the maintenance speci-


Safety

fications.

Misuse

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


misuse and is not allowed. This includes e.g.:
• Use as a climbing aid
• Operation outside the specified operating parameters
• Operation without the required safety equipment

5.1.3 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:
• 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 EC 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.

5.1.4 Terms used

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


EN 60204-1:2006.

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Safety
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.
Danger zone The danger zone consists of the workspace and the stopping distan-
ces of the manipulator and external axes (optional).
Service life The service life of a safety-relevant component begins at the time of
delivery of the component to the customer.
The service life is not affected by whether the component is used or
not, as safety-relevant components are also subject to aging during
storage.
KUKA smartPAD see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safe operational stop The safe operational stop is a standstill monitoring function. It does
not stop the robot motion, but monitors whether the robot axes are
stationary. If these are moved during the safe operational stop, a
safety stop STOP 0 is triggered.
The safe operational stop can also be triggered externally.
When a safe operational stop is triggered, the robot controller sets
an output to the field bus. The output is set even if not all the axes
were stationary at the time of triggering, thereby causing a safety
stop STOP 0 to be triggered.
Safety STOP 0 A stop that is triggered and executed by the safety controller. The
safety controller immediately switches off the drives and the power
supply to the brakes.
Note: This stop is called safety STOP 0 in this document.
Safety STOP 1 A stop that is triggered and monitored by the safety controller. The
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 deactivates the
drives and the power supply of the brakes.
When a safety STOP 1 is triggered, the robot controller sets an out-
put 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 manipula-
tor is at a standstill, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an out-
put to the field bus.
The safety STOP 2 can also be triggered externally.

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Term Description
Note: This stop is called safety STOP 2 in this document.
Safety options Generic term for options which make it possible to configure addition-
al safe monitoring functions in addition to the standard safety func-
tions.
Example: SafeOperation
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.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-orien-
ted braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-main-
taining braking.

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


robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C4), AUT EXT (KR C4), EXT
(VKR C4):
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-orien-
Drive Ramp Stop ted 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 (KR C4), AUT EXT (KR C4), EXT
(VKR C4):
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)
External axis Axis of motion that does not belong to the manipulator, yet is control-
led with the robot controller. e.g. KUKA linear unit, turn-tilt table, Pos-
iflex

5.2 Personnel

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

• User
• Personnel

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Safety
All persons working with the industrial robot must have read and under-
stood 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.

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

Installation, exchange, adjustment, operation, maintenance and repair


must be performed only as specified in the operating or assembly in-
structions for the relevant component of the industrial robot and only by
personnel specially trained for this purpose.

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

Work on the electrical and mechanical equipment of the industrial robot


may only be carried out by specially trained personnel.

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5.3 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.

5.3.1 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.

5.4 Triggers for stop reactions

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 STOP 2
drops out
Power switched off via STOP 0
main switch or power
failure
Internal error in non- STOP 0 or STOP 1
safety-oriented part of
(dependent on the cause of the error)
the robot controller

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Safety
Trigger T1, T2 AUT, AUT EXT
Operating mode Safety stop 2
changed during opera-
tion
Safety gate opened (op- - Safety stop 1
erator safety)
Enabling switch released Safety stop 2 -
Enabling switch pressed Safety stop 1 -
fully down or error
E-STOP pressed Safety stop 1
Error in safety controller Safety stop 0
or periphery of the safety
controller

5.5 Safety functions

5.5.1 Overview of the safety functions

The following safety functions are present in the industrial robot:


• Selecting the operating mode
• Operator safety (= connection for the monitoring of physical safe-
guards)
• EMERGENCY STOP device
• Enabling device
• External safe operational stop
• External safety stop 1
• External safety stop 2
• 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 following components are involved in the safety functions:
• Safety controller in the control PC
• KUKA smartPAD
• Cabinet Control Unit (CCU)
• Resolver Digital Converter (RDC)
• KUKA Power Pack (KPP)
• KUKA Servo Pack (KSP)
• Safety Interface Board (SIB) (if used)
There are also interfaces to components outside the industrial robot and
to other robot controllers.

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DANGER
In the absence of operational safety functions and safeguards, the in-
dustrial robot can cause personal injury or material damage. If safety
functions or safeguards are dismantled or deactivated, the industrial ro-
bot may not be operated.

During system planning, the safety functions of the overall system must
also be planned and designed. The industrial robot must be integrated
into this safety system of the overall system.

5.5.2 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

5.5.3 Selecting the operating mode

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.

Operat-
ing 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
controllers Programmed velocity

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Safety
Operat-
ing Use Velocities
mode
• 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

WARNING
If the smartPAD is fitted with a switch without a key:
An additional device must be present to ensure that the relevant func-
tions cannot be executed by all users, but only by a restricted group of
people.
The device itself must not trigger motions of the industrial robot or
other hazards. If this device is missing, death or severe injuries may re-
sult.

The system integrator is responsible for ensuring that such a device is im-
plemented.

5.5.4 “Operator safety” signal

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
Following a loss of signal, automatic operation may only be resumed
when the safeguard has been closed and when the closing has been
acknowledged. This acknowledgement is to prevent automatic operation
from being resumed inadvertently while there are still persons in the
danger zone, e.g. due to the safety gate closing accidentally.
The acknowledgement must be designed in such a way that an actual
check of the danger zone can be carried out first. Other acknowledge-
ment functions (e.g. an acknowlegement which is automatically trig-
gered by closure of the safeguard) are not permitted.
The system integrator is responsible for ensuring that these criteria are
met. Failure to met them may result in death, severe injuries or consid-
erable damage to property.

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5.5.5 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
Tools and other equipment connected to the robot must be integrated
into the EMERGENCY STOP circuit on the system side if they could
constitute a potential hazard.
Failure to observe this precaution may result in death, severe injuries
or considerable damage to property.

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.
(>>> 5.5.7 "External EMERGENCY STOP device" Page 45)

5.5.6 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:
• Switching off the voltage via the main switch of the robot
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.

If the Ethernet safety interface is used: In his risk assessment, the sys-
tem integrator must take into consideration whether the fact that switch-
ing off the robot controller does not trigger an EMERGENCY STOP of
the overall system could constitute a hazard and, if so, how this hazard
can be countered.
Failure to take this into consideration may result in death, injuries or
damage to property.

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WARNING
If a robot controller is switched off, the E-STOP device on the smart-
PAD is no longer functional. The user is responsible for ensuring that
the smartPAD is either covered or removed from the system. This
serves to prevent operational and non-operational EMERGENCY STOP
devices from becoming interchanged.
Failure to observe this precaution may result in death, injuries or dam-
age to property.

5.5.7 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.

5.5.8 Enabling device

The enabling devices of the industrial robot are the enabling switches on
the smartPAD.
There are 3 enabling switches installed on the smartPAD. The enabling
switches have 3 positions:
• Not pressed
• Center position
• Panic position
In the test modes, the manipulator can only be moved if one of the ena-
bling switches is held in the central position.
• Releasing the enabling switch triggers a safety stop 2.
• Pressing the enabling switch down fully (panic position) triggers a
safety stop 1.
• It is possible to hold 2 enabling switches in the center position simul-
taneously for up to 15 seconds. This makes it possible to adjust grip
from one enabling switch to another one. If 2 enabling switches are
held simultaneously in the center position for longer than 15 seconds,
this triggers a safety stop 1.
If an enabling switch malfunctions (e.g. jams in the central position), the
industrial robot can be stopped using the following methods:

• Press the enabling switch down fully.


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

WARNING
The enabling switches must not be held down by adhesive tape or oth-
er means or tampered with in any other way.
Death, injuries or damage to property may result.

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5.5.9 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.
External enabling devices are not included in the scope of supply of the
industrial robot.
Which interface can be used for connecting external enabling devices
is described in the “Planning” chapter of the robot controller operating
instructions and assembly instructions.

5.5.10 External safe operational stop

The safe operational stop can be triggered via an input on the customer
interface. The state is maintained as long as the external signal is FALSE.
If the external signal is TRUE, the manipulator can be moved again. No
acknowledgement is required.

5.5.11 External safety stop 1 and external safety stop 2

Safety stop 1 and safety stop 2 can be triggered via an input on the cus-
tomer interface. The state is maintained as long as the external signal is
FALSE. If the external signal is TRUE, the manipulator can be moved
again. No acknowledgement is required.
If interface X11 is selected as the customer interface, only the signal
Safety stop 2 is available.

5.5.12 Velocity monitoring in T1

The velocity at the mounting flange is monitored in T1 mode. If the veloc-


ity exceeds 250 mm/s, a safety stop 0 is triggered.

5.6 Additional protective equipment

5.6.1 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.
• 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.

5.6.2 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.

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

5.6.3 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
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator can no lon-
ger be operated safely. The manipulator must be taken out of operation
and KUKA Deutschland GmbH must be consulted before it is put back
into operation.

5.6.4 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 KUKA Deutschland GmbH.

5.6.5 Options for moving the manipulator without drive energy

The system user is responsible for ensuring that the training of person-
nel with regard to the response to emergencies or exceptional situa-
tions also includes how the manipulator can be moved without drive en-
ergy.

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.

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Information about the options available for the various robot models
and about how to use them can be found in the assembly and operat-
ing instructions for the robot or requested from KUKA Deutschland
GmbH.

NOTICE
Moving the manipulator without drive energy can damage the motor
brakes of the axes concerned. The motor must be replaced if the brake
has been damaged. The manipulator may therefore be moved without
drive energy only in emergencies, e.g. for rescuing persons.

5.6.6 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


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

5.6.7 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.

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• 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


regulations. 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.

5.7 Overview of operating modes and safety functions

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 de-
Active Active Active Active
vice
Enabling device Active Active - -
Reduced velocity during
Active - - -
program verification
Jog mode Active Active - -
Software limit switches Active Active Active Active

5.8 Safety measures

5.8.1 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
In the absence of operational safety functions and safeguards, the in-
dustrial robot can cause personal injury or material damage. If safety
functions or safeguards are dismantled or deactivated, the industrial ro-
bot may not be operated.

DANGER
Standing underneath the robot arm can cause death or injuries. For this
reason, standing underneath the robot arm is prohibited!

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CAUTION
The motors reach temperatures during operation which can cause
burns to the skin. Contact must be avoided. Appropriate safety precau-
tions must be taken, e.g. protective gloves must be worn.

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
The operator must ensure that decoupled smartPADs are immediately
removed from the system and stored out of sight and reach of person-
nel working on the industrial robot. This serves to prevent operational
and non-operational EMERGENCY STOP devices from becoming inter-
changed.
Failure to observe this precaution may result in death, severe injuries
or considerable damage to property.

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.

5.8.2 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.

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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.

5.8.3 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be
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.
The passwords for the user groups must be changed in the KUKA Sys-
tem Software before start-up. The passwords must only be communica-
ted to authorized personnel.

WARNING
The robot controller is preconfigured for the specific industrial robot. If
cables are interchanged, the manipulator and the external axes (option-
al) may receive incorrect data and can thus cause personal injury or
material damage. If a system consists of more than one manipulator, al-
ways connect the connecting cables to the manipulators and their cor-
responding robot controllers.

If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Deutschland GmbH, are integrated into the industrial
robot, the user is responsible for ensuring that these components do
not adversely affect or disable safety functions.

NOTICE
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form, which may
cause damage to the electrical components. Do not put the robot con-
troller into operation until the internal temperature of the cabinet has
adjusted to the ambient temperature.

Function test

The following tests must be carried out before start-up and 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.

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• There is no damage to the robot that could be attributed to external


forces. Examples: Dents or abrasion that could be caused by an im-
pact or collision.
WARNING
In the case of such damage, the affected components must be ex-
changed. In particular, the motor and counterbalancing system must
be checked carefully.
External forces 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 manipulator. Death, injuries or consid-
erable damage to property may otherwise result.

• There are no foreign bodies or loose parts on the industrial robot.


• All required safety equipment is correctly installed and operational.
• The power supply ratings of the industrial robot correspond to the
local supply voltage and mains type.
• The ground conductor and the equipotential bonding cable are 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

5.8.3.1 Checking machine data and safety configuration

WARNING
The industrial robot must not be moved if incorrect machine data or an
incorrect controller configuration are loaded. Death, severe injuries or
considerable damage to property may otherwise result. The correct da-
ta must be loaded.

• 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.
• 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.
• System Software 8.3 or higher: If the checksum of the safety configu-
ration has changed, the safe axis monitoring functions must be
checked.

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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.
Second part:
• 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.

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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 KUKA linear unit

If practical tests are required for the machine data, this test must be car-
ried out if the robot and KL are mathematically coupled.
• Move the KL manually in Cartesian mode.
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.

5.8.3.2 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
• System Software 8.2 or earlier:
Start-up mode is always possible if all input signals at the discrete
safety interface have the state “logic zero”. If this is not the case, the
robot controller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the
inputs there must also have the state “logic zero”.
• System Software 8.3 or higher:
Start-up mode is always possible. This also means that it is independ-
ent of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.

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Ethernet safety interface

Safety
The robot controller prevents or terminates Start-up mode if a connection
to a higher-level safety system exists or is established.

Effect

When the Start-up mode is activated, all outputs are automatically set to
the state “logic zero”.
If the robot controller has a peripheral contactor (US2), and if the safety
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.
NOTICE
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
Use of Start-up mode disables all external safeguards. The service per-
sonnel are responsible for ensuring that there is no-one in or near the
danger zone of the manipulator as long as the safeguards are disabled.
Failure to observe this precaution may result in death, injuries or dam-
age to property.

Misuse

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


misuse and is not allowed. KUKA Deutschland GmbH is not liable for any
damage resulting from such misuse. The risk lies entirely with the user.

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5.8.4 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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Safety
• 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.

5.8.5 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.

5.8.6 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.

5.8.7 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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DANGER
Before work is commenced on live parts of the robot system, the main
switch must be turned off and secured against being switched on
again. The system must then be checked to ensure that it is deener-
gized.
It is not sufficient, before commencing work on live parts, to execute an
EMERGENCY STOP or a safety stop, or to switch off the drives, as
this does not disconnect the robot system from the mains power
supply. Parts remain energized. Death or severe injuries may result.

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.
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.
The hydropneumatic and gas cylinder counterbalancing systems are pres-
sure equipment and, as such, are subject to obligatory equipment monitor-
ing and the provisions of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and
standards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety
Order, Sections 14 and 15. Inspection by the user before commissioning
at the installation site.
The following safety measures must be carried out when working on the
counterbalancing system:
• The manipulator assemblies supported by the counterbalancing sys-
tems 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.

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To ensure safe use of our products, we recommend regularly request-
ing up-to-date safety data sheets for hazardous substances.

5.8.8 Decommissioning, storage and disposal

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


accordance with the applicable national laws, regulations and standards.

5.8.9 Safety measures for “single point of control”

Overview

If certain components in the industrial robot are operated, 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

The implementation of additional safety measures may be required.


This must be clarified for each specific application; this is the responsi-
bility of the system integrator, programmer or user of the system.

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.

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.
Safety measures:

• In T1 and T2, the system variable $OV_PRO must not be written to


by the submit interpreter or the PLC.

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• Do not modify safety-relevant signals and variables (e.g. operating


mode, EMERGENCY STOP, safety gate contact) via the submit inter-
preter or PLC.
If modifications are nonetheless required, all safety-relevant signals
and variables must be linked in such a way that they cannot be set to
a dangerous state by the submit interpreter or PLC. This is the re-
sponsibility of the system integrator.

OPC server, 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.

5.9 Applied norms and regulations

Name/Edition Definition

2006/42/EU: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

2014/68/EU:2014 Pressure Equipment Directive:


Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)

EN ISO 13850:2015 Safety of machinery:


Emergency stop - Principles for design

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Safety
EN ISO 13849-1:2015 Safety of machinery:
Safety-related parts of control systems - Part 1: General principles
of design

EN ISO 13849-2:2012 Safety of machinery:


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

EN ISO 12100:2010 Safety of machinery:


General principles of design, risk assessment and risk reduction

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


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

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


Ergonomic design principles - Part 1: Terms and general principles

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 60204-1:2006/ Safety of machinery:


A1:2009
Electrical equipment of machines - Part 1: General requirements

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Planning KR C4 extended

6 Planning
Overview

Step Description Information


1 Electromagnetic compati- (>>> 6.1 "Electromagnetic com-
bility (EMC) patibility (EMC)" Page 62)
2 Installation conditions for (>>> 6.2 "Installation condi-
robot controller tions" Page 63)
3 Connection conditions (>>> 6.3 "Connection condi-
tions" Page 64)
4 Installation of the KUKA (>>> 6.4 "Fastening the KUKA
smartPAD holder (option- smartPAD holder (optional)"
al) Page 65)
5 Interfaces (>>> 6.5 "Overview of lower in-
terfaces" Page 66)
6 Power supply connection (>>> 6.5.1 "Power supply con-
via X1 nection via Harting connector
X1" Page 67)
7 EtherCAT connection on (>>> 6.8 "EtherCAT connection
the CIB on the CIB" Page 86)
8 RDC connection exam- (>>> 6.9 "Motor box and RDC
ples box connection examples"
Page 87)
9 PE equipotential bonding (>>> 6.10 "PE equipotential
bonding" Page 87)
10 Modification of the sys- (>>> 6.11 "Modifying the sys-
tem structure, exchange tem configuration, exchanging
of devices devices" Page 89)
11 Acknowledgment of oper- (>>> 6.12 "Operator safety ac-
ator safety knowledgement" Page 89)
12 Performance level (>>> 6.13 "Performance level"
Page 89)

6.1 Electromagnetic compatibility (EMC)

Description

If connecting cables (e.g. field buses, etc.) are routed to the control PC
from outside, only shielded cables with an adequate degree of shielding
may be used. The cable shield must be connected with maximum surface
area to the PE rail in the cabinet using shield terminals (screw-type, no
clamps).
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.
Assuring the electromagnetic compatibility in other environments may
be difficult due to conducted and radiated disturbances that are liable to
occur.

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6.2 Installation conditions

The minimum clearances that must be maintained for the robot controller
are indicated in the diagram (>>> Fig. 6-1).

Fig. 6-1: Minimum clearances

NOTICE
If the minimum clearances are not maintained, this can result in dam-
age to the robot controller. The specified minimum clearances must al-
ways be observed.

Certain maintenance and repair tasks on the robot controller


(>>> 10 "Maintenance" Page 108) (>>> 11 "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.

The diagram (>>> Fig. 6-2) shows the swing range for the door.

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Fig. 6-2: Swing range for cabinet door

Swing range, standalone cabinet:


• Door with computer frame approx. 180°
Swing range, butt-mounted cabinets:
• Door approx. 155°

6.3 Connection conditions

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


supply systems.

Power supply connection

Rated supply voltage, optionally: 3x380 V AC, 3x400 V AC


Permissible tolerance of rated Rated supply voltage ±10%
supply voltage
Mains frequency 49 ... 61 Hz
System impedance up to the con- ≤ 300 mΩ
nection point of the robot control-
ler
Full-load current See rating plate
Mains-side fusing with KPP G1 min. 3x50 A, slow-blowing
and G11
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit.

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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
material damage to the power supply units. Electrical voltage can
cause injuries. The robot controller may only be operated with groun-
ded-neutral power supply systems.

NOTICE
If the robot controller is operated with a supply voltage other than that
specified on the rating plate, this may cause malfunctions in the robot
controller and material damage to the power supply units. The robot
controller may only be operated with the supply voltage specified on
the rating plate.

The appropriate machine data must be loaded in accordance with the


rated supply voltage.

If use of a residual-current circuit-breaker (RCCB) is planned, it must


be borne in mind that a residual current of up to 600 mA can be ex-
pected in faultless operation. An RCCB of this rating serves the pur-
pose of equipment protection but not of personnel protection. We rec-
ommend the following RCCB: universal-current sensitive, selective.

Cable lengths

For cable designations, standard lengths and optional lengths, please


refer to the operating instructions or assembly instructions of the manipu-
lator and/or the assembly and operating instructions for KR C4 external
cabling for robot controllers.
When using smartPAD cable extensions, only two extensions may be
used. An overall cable length of 50 m must not be exceeded.

The difference in the cable lengths between the individual channels of


the RDC box must not exceed 10 m.

The maximum permissible length of the robot connecting cable set is


10 m.

6.4 Fastening the KUKA smartPAD holder (optional)

Overview

The smartPAD holder can be installed on the door of the robot controller
or on the safety fence.
The following diagram (>>> Fig. 6-3) shows the options for fastening the
smartPAD holder.

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Fig. 6-3: smartPAD holder

1 M6x12 Allen screw 3 Door of robot controller


2 Spring lock washer A6.1 and 4 Iron flat for fence mounting
plain washer

6.5 Overview of lower interfaces

The robot controller variant KR C4 extended ready2_rivet comprises the


following interfaces:
• X20 motor connector
• X7.1 single connector
• X1 power supply connection
• X51 cable inlet
• X56 load voltages US1/US2
• X55 external power supply
• X67.1 X67.2 X67.3 KLI interfaces
• X65 EtherCAT interface
• X19 KUKA smartPAD
• X21 data cable
• X42 reference switch

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Lower connection panel

Fig. 6-4: Connection panel overview

1 X1 power supply connection


2 Motor connector interfaces
3 X7.1 motor connector for external axis
4 X51 cable inlet
5 X65 EtherCAT interface
6 X56 load voltages US1/US2
7 X67.1 PROFINET interface
8 X67.2 PROFINET interface
9 X19 smartPAD connection
10 X42 reference switch
11 X21 data cable
12 X67.3 PROFINET interface
13 X55 external power supplies
14 XP7.1 data interface, external axis
15 SL1 ground conductor to manipulator
16 SL2 ground conductor to main infeed

All contactor, relay and valve coils that are connected to the robot con-
troller by the user must be equipped with suitable suppressor diodes.
RC elements and VCR resistors are not suitable.

6.5.1 Power supply connection via Harting connector X1

Description

A Harting connector bypack is supplied with the robot controller. The cus-
tomer can connect the robot controller to the power supply via connector
X1.

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Fig. 6-5: Power supply connection X1

1 Harting connector bypack (optional)


2 Power supply connection X1

6.5.2 Motor interfaces

Description

The motors and brakes of the robot controller or the external axes are
connected to the robot controller via the following motor connectors. Two
possible connector inserts for an individual axis are shown below. The
connector inserts can be combined to multiple connectors.
The following sections show the internal cabling as well as the combina-
tions of connector inserts that are possible to multiple connectors.

Necessary equipment

• Cable 3X AWG8
• Cable 2X AWG18
• Harting connector, HAN Modular

Fig. 6-6: Connector contact diagram, connector side

Connector pin allocation

Pin Description
1 Motor U1
2 Motor V1
3 Motor W1
11 Brake 24 V
12 Brake 0 V

Necessary equipment

• Cable 3X AWG12
• Cable 2X AWG18

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• Harting connector, HAN E Modular

Fig. 6-7: Connector contact diagram, connector side

Connector pin allocation

Pin Description
1 Motor U1
2 Not assigned
3 Brake 24 V
4 Motor V1
5 Brake 0 V
6 Motor W1
In the circuit diagram, the letter for the relevant connecter insert is placed
in front of the pin numbers.

6.5.2.1 Motor connector X20, KPP and KSP

Fig. 6-8: Connector inserts

Motor connector X20

Connec-
Axis Axis servos Connection
tor insert
A1 A KSP T2 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KSP T1 X1/X31
A5 E X2/X32
A6 F X3/X33

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6.5.2.2 Motor connector X7.1, external axis 1


Planning

Fig. 6-9: Connector inserts

Motor connector X7.1

Connec-
Axis Axis servo Connection
tor insert
A7 A KPP G1 X2/X32

6.5.3 Cable inlet X51

Description

Four-fold cable inlet for digital inputs/outputs

Overview

Fig. 6-10: Cable inlet X51

1 Cable inlet clamping range 4.5 ... 10 mm


2 Cable inlet clamping range 9 ... 15 mm

6.5.4 X56 load voltages US1/US2

Description

In the case of interfaces with load voltage US1/US2, load voltage US1 is
not switched and US2 is implemented as switchable using safe technology
so that actuators, for example, are switched off when the drives are deac-
tivated.
This function exists in the following three variants and is set in the safety
configuration:
• Switched by an external PLC:
The contactor is switched directly by an external input (US2 signal in
the PROFIsafe/CIP Safety/FSoE telegram). This variant is available
only if PROFIsafe/CIP Safety/FSoE is in use.
• Switched by the KRC:
The contactor is switched if the “FF signal” and the non-safe
“US2_CONTACTOR_ON” signal from the robot controller are set. In

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this way, the non-safe part of the robot controller can also switch the

Planning
contactor.
• Deactivated:
The contactor is always off.
If, due to a fault in the system cabling, there is a cross connection be-
tween US1 and US2, this will not be noticed during normal operation. The
result is that load voltage US2 is no longer switched off which can lead to
a dangerous state in the system.
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accord-


ance with .

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary equipment

• Male insert, Han Q7/0

Fig. 6-11: Contact diagram, view from contact side

• Cable clamping range: Ø9 ... Ø13 mm


• Recommended wire cross-section: 1.5 mm 2

Connector pin allocation X56

Pin Description
1 US1 +24 V / 5 A (F6)
2 US1 0 V
3 US2 +24 V / 7 A (F301)
4 US2 0 V
- PE
The load voltage US2 is switched via contactors Q5 and Q6. The fuses
are located on the CCU_SR.

6.5.5 X55 external power supply

Description

The following couplers can be supplied with power via connector X55:
• Switch

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Necessary equipment

• Male insert, HAN 8D

Fig. 6-12: Contact diagram, view from contact side

• Cable clamping range: Ø9 ... Ø13 mm


• Recommended wire cross-section: 1 mm2

Connector pin allocation X55

Pin Description
5 +24 V external
6 0 V external
7 +24 V internal
8 0 V internal
- PE

6.5.6 X67.1, X67.2 and X67.3 KLI interfaces

Description

The Ethernet interfaces X67.1, X67.2 and X67.3 can be used to connect
the KUKA Line Interface to the system, for example, or to connect a com-
puter to the robot controller.

Necessary equipment

• RJ45 connector

Fig. 6-13: RJ-45 pin assignment

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• Recommended connecting cable: Ethernet-compatible, min. category
CAT 5E
• Maximum cable cross-section: AWG22

Connector pin allocation X67.1, X67.2, X67.3

Pin Description
1 TD+
2 TD-
3 RD+
6 RD-

6.5.7 X65 EtherCAT interface

Description

Connector X65 in the connection panel is the interface for connection of


EtherCAT slaves outside the robot controller. The EtherCAT line is routed
out of the robot controller.
The EtherCAT devices must be configured with WorkVisual.

Necessary equipment

• RJ45 connector

Fig. 6-14: RJ-45 pin assignment

• Recommended connecting cable: PROFINET-compatible, min. catego-


ry CAT 5e
• Maximum cable cross-section: AWG22

Connector pin allocation X65 via bus coupler

Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
6 TPFI_N

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6.5.8 X19 KUKA smartPAD

Description

The KUKA smartPAD is connected to interface X19.

Necessary equipment

• Intercontec series 615

Fig. 6-15: Contact diagram, view from contact side

Connector pin allocation X19

Pin Description
11 TD+
12 TD-
2 RD+
3 RD-
8 smartPAD plugged in (A) 0 V
9 smartPAD plugged in (B) 24 V
5 24 V PS2
6 GND

6.5.9 X21 US2 RDC interface

Description

For the X21 US2 RDC interface, the buffered US1 voltage is used to sup-
ply power to the RDC of the robot. The US2 voltage is implemented as
switchable using safe technology. This deactivates actuators via a Beckh-
off board, for example, when the drives are deactivated.
This function exists in the following three variants and is set in the safety
configuration:
• Switched by an external PLC:
The contactor is switched directly by an external input (US2 signal in
the PROFIsafe/CIP Safety/FSoE telegram). This variant is available
only if PROFIsafe/CIP Safety/FSoE is in use.
• Switched by the KRC:
The contactor is switched if the “FF signal” and the non-safe
“US2_CONTACTOR_ON” signal from the robot controller are set. In
this way, the non-safe part of the robot controller can also switch the
contactor.
• Deactivated:
The contactor is always off.
If, due to a fault in the system cabling, there is a cross connection be-
tween US1 and US2, this will not be noticed during normal operation. The

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result is that load voltage US2 is no longer switched off which can lead to

Planning
a dangerous state in the system.
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accord-


ance with .

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary equipment

• Harting HAN3A/Q12

Fig. 6-16: Contact diagram, view from contact side

Connector pin allocation X21

Pin Description
1 +24 V with battery back-up
2 GND
5 US2 +24 V switched
6 GND
9 TD+
11 TD-
10 RD+
12 RD-
- PE
Voltage US2 is switched via contactors Q5 and Q6. The fuse is located
on the CCU_SR.

6.5.10 X42 reference switch

Description

The reference switch X42 is needed to carry out the mastering test.
Detailed information about the mastering test can be found in the
KUKA.SafeOperation documentation.

Necessary equipment

• Cable 5xAWG16

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• Connector M17 7-pole

Fig. 6-17: Contact diagram, view from contact side

Connector pin allocation X42

Pin Description
1 TA24V A
4 TA24V B
2 E_REF_A_24V
5 E_REF_B_24V
6 Not assigned
3 GND

6.6 Discrete interfaces for safety options

6.6.1 Safety functions via Ethernet safety interface

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 safe inputs can be pre-assigned by a PLC with the values 0 or


1. In both cases, the manipulator will move. If a safety function is as-
signed 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

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Bit Signal Description
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
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
options in the safety configuration. Information is
contained in the Operating and Programming In-
structions 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 -

Input byte 1

Bit Signal Description


0 US2 Supply voltage US2 (signal for switching the sec-
ond supply voltage, US2, without battery backup)
If this output is not used, it should be set to 0.

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Bit Signal Description


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 In-
tegrators.
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 pow-
er-down signal. A second after the “SP” (System
Powerdown) 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

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 in the
KRC 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)

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Bit Signal Description
1 = drives enable is active (the robot controller
must switch the drives to servo-control)
2 FF Motion enable (the internal safety controller in the
KRC 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 (sig-
nal ZSE1/ZSE2).
• Robot can be moved (no external EMERGEN-
CY 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

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 SHS1 Safety stop 1 (all axes)

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Bit Signal Description


0 = safety stop 1 is not active
1 = safety stop 1 is active (safe state reached)
3 SHS2 Safety stop 2 (all axes)
0 = safety stop 2 is not active
1 = safety stop 2 is active (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

6.6.1.1 Schematic circuit diagram for enabling switches

Description

An external enabling switch can be connected to the higher-level safety


controller. The signals (ZSE make contact and External panic break con-
tact) must be correctly linked to the Ethernet safety interface signals in the
safety controller. The resulting Ethernet safety interface signals must then
be routed to the PROFIsafe of the KR C4. The response to the external
enabling switch is then identical to that for a discretely connected X11.

Signals

Fig. 6-18: Schematic circuit diagram of external enabling switch

• Enabling switch center position (make contact closed (1) = enabled)


OR AUT at SHS2
• Panic (break contact open (0) = panic position) = AND not AUT at
SHS1

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6.6.1.2 SafeOperation via Ethernet safety interface (optional)

Planning
Description

The components of the industrial robot move within the limits that have
been configured and activated. The actual positions are continuously cal-
culated and monitored against the safety parameters that have been set.
The safety controller monitors the industrial robot by means of the safety
parameters that have been set. If a component of the industrial robot vio-
lates a monitoring limit or a safety parameter, the manipulator and
external axes (optional) are stopped. The Ethernet safety interface can be
used, for example, to signal a violation of safety monitoring functions.
In the case of the KR C4 compact or KR C4 compact slimline robot con-
troller, safety options such as SafeOperation are only available via the
Ethernet safety interface from KSS/VSS 8.3 onwards.

Reserved bits

Reserved safe inputs can be pre-assigned by a PLC with the values 0 or


1. In both cases, the manipulator will move. If a safety function is as-
signed 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 2

Bit Signal Description


0 JR Mastering test (input for the reference switch
of the mastering test)
0 = reference switch is active (actuated).
1 = reference switch is not active (not actu-
ated).
1 VRED Reduced axis-specific and Cartesian velocity
(activation of reduced velocity monitoring)
0 = reduced velocity monitoring is active.
1 = reduced velocity monitoring is not active.
2 … 7 SBH1 … 6 Safe operational stop for axis group 1 ... 6
Assignment: Bit 2 = axis group 1 … bit 7 =
axis group 6
Signal for safe operational stop. The function
does not trigger a stop, it only activates the
safe standstill monitoring. Cancelation of this
function does not require acknowledgement.
0 = safe operational stop is active.
1 = safe operational stop is not active.

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Input byte 3

Bit Signal Description


0 … 7 RES Reserved 25 … 32
The value 1 must be assigned to the inputs.

Input byte 4

Bit Signal Description


0 … 7 UER1 … 8 Monitoring spaces 1 … 8
Assignment: Bit 0 = monitoring space 1 … bit
7 = monitoring space 8
0 = monitoring space is active.
1 = monitoring space is not active.

Input byte 5

Bit Signal Description


0 … 7 UER9 … 16 Monitoring spaces 9 … 16
Assignment: Bit 0 = monitoring space 9 … bit
7 = monitoring space 16
0 = monitoring space is active.
1 = monitoring space is not active.

Input byte 6

Bit Signal Description


0 … 7 WZ1 … 8 Tool selection 1 … 8
Assignment: Bit 0 = tool 1 … bit 7 = tool 8
0 = tool is not active.
1 = tool is active.
Exactly one tool must be selected at all
times.

Input byte 7

Bit Signal Description


0 … 7 WZ9 … 16 Tool selection 9 … 16
Assignment: Bit 0 = tool 9 … bit 7 = tool 16
0 = tool is not active.
1 = tool is active.
Exactly one tool must be selected at all
times.

Output byte 2

Bit Signal Description


0 SO Activation status of the safety option
0 = safety option is not active.

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Bit Signal Description
1 = safety option is active
1 RR Robot referenced
Mastering test display
0 = mastering is not referenced.
1 = mastering test performed successfully.
2 JF Mastering error
The space monitoring is deactivated if at
least one axis is not mastered.
0 = mastering error. Space monitoring has
been deactivated.
1 = no error.
3 VRED Reduced axis-specific and Cartesian velocity
(activation status of reduced velocity monitor-
ing)
0 = reduced velocity monitoring is not active.
1 = reduced velocity monitoring is active.
4 … 7 SBH1 ... 4 Activation status of safe operational stop for
axis group 1 ... 4
Assignment: Bit 4 = axis group 1 … bit 7 =
axis group 4
0 = safe operational stop is not active.
1 = safe operational stop is active.

Output byte 3

Bit Signal Description


0 … 1 SBH5 … 6 Activation status of safe operational stop for
axis group 5 ... 6
Assignment: Bit 0 = axis group 5 … bit 1 =
axis group 6
0 = safe operational stop is not active.
1 = safe operational stop is active.
2 SOS Safe Operation Stop
0 = a safety function has triggered a stop.
The output remains in the “0” state for at
least 200 ms.
1 = none of the safety functions has triggered
a stop.
Note: The output SOS is available in System
Software 8.3 or higher. In System Software
8.2 or lower, bit 2 is a spare bit.
3 … 7 RES Reserved 28 ... 32

Output byte 4

Bit Signal Description


0 … 7 MR1 … 8 Alarm space 1 … 8

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Bit Signal Description


Assignment: Bit 0 = alarm space 1 (associ-
ated monitoring space 1) … bit 7 = alarm
space 8 (associated monitoring space 8)
0 = monitoring space is violated.
1 = monitoring space is not violated.
Note: An inactive monitoring space is consid-
ered to be violated by default, i.e. in this
case the associated safe output MRx has the
state “0”.

Output byte 5

Bit Signal Description


0 … 7 MR9 … 16 Alarm space 9 … 16
Assignment: Bit 0 = alarm space 9 (associ-
ated monitoring space 9) … bit 7 = alarm
space 16 (associated monitoring space 16)
0 = monitoring space is violated.
1 = monitoring space is not violated.
Note: An inactive monitoring space is consid-
ered to be violated by default, i.e. in this
case the associated safe output MRx has the
state “0”.

Output byte 6

Bit Signal Description


0 … 7 RES Reserved 49 ... 56

Output byte 7

Bit Signal Description


0 … 7 RES Reserved 57 ... 64

6.7 Overview of side interfaces

The robot controller variant KR C4 extended ready2_rivet comprises the


following interfaces:
• XS1EC, XS2EC, XS5EC: EtherCAT interfaces for Böllhoff peripheral
equipment
• XS1EP, XS2EP, XS5EP: 24 V DC supply for Böllhoff peripheral equip-
ment

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Side connection panel

Fig. 6-19: Connection panel overview

1 XS1EC: EtherCAT interface for Böllhoff peripheral equipment


2 XS2EC: EtherCAT interface for Böllhoff peripheral equipment
3 XS1EP: 24 V DC supply for Böllhoff peripheral equipment
4 XS2EP: 24 V DC supply for Böllhoff peripheral equipment
5 XS5EP: 24 V DC supply for Böllhoff peripheral equipment
6 XS5EC: EtherCAT interface for Böllhoff peripheral equipment

All contactor, relay and valve coils that are connected to the robot con-
troller by the user must be equipped with suitable suppressor diodes.
RC elements and VCR resistors are not suitable.

6.7.1 XS1EC, XS2EC, XS5EC: EtherCAT interfaces for Böllhoff peripheral


equipment

Description

The Ethernet interfaces XS1EC, XS2EC and XS5EC can be used to con-
nect the Böllhoff peripheral equipment to the KUKA Line Interface, e.g. to
the system, or to connect a computer to the robot controller.

Necessary equipment

• RJ45 connector

Fig. 6-20: RJ-45 pin assignment

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• Recommended connecting cable: Ethernet-compatible, min. category


CAT 5E
• Maximum cable cross-section: AWG22

Connector pin allocation XS1EC, XS2EC, XS5EC

Pin Description
1 TD+
2 TD-
3 RD+
6 RD-

6.7.2 XS1EP, XS2EP, XS5EP: 24 V DC supply for Böllhoff peripheral equip-


ment

Description

Böllhoff peripheral equipment is supplied with a voltage of 24 V DC via in-


terfaces XS1EP, XS2EP, XS5EP.

Necessary equipment

• AIDA Power

Connector pin allocation XS1EP, XS2EP, XS5EP

Pin Description
1 Us
2 GND
3 Up
4 GND
PE Mass

6.8 EtherCAT connection on the CIB

Description

Connector X44 on the CIB is the interface for connection of EtherCAT


slaves inside the robot controller (on the mounting plate for customer com-
ponents). The EtherCAT line remains in the robot controller. The EtherCAT
line can be routed out of the robot controller via the optional connector
X65. Information about connector X65 can be found in the assembly and
operating instructions of the optional KR C4 interfaces.
The EtherCAT devices must be configured with WorkVisual.

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Fig. 6-21: EtherCAT connection X44

1 CIB
2 EtherCAT connection X44

6.9 Motor box and RDC box connection examples

Description

The diagram (>>> Fig. 6-22) shows a system with a manipulator with 6
axes and 8 single axes. The RDC boxes are connected in series (cas-
cade).

Fig. 6-22: Example: 14 axes

1 Connection panel on KR C4 extended robot controller


2 Motor
3 Motor cable for single axis
4 Resolver cable for single axis
5 Manipulator
6 Data cable between manipulator and robot controller, X21
7 Motor cable between manipulator and robot controller

6.10 PE equipotential bonding

Description

The following cables must be connected before start-up:

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• A 16 mm2 cable as equipotential bonding between the robot kinematic


system and the robot controller.
• An additional 16 mm2 PE conductor between the central PE rail of the
supply cabinet and the PE bolt of the robot controller.

Fig. 6-23: Equipotential bonding via cable duct

1 PE to central PE rail of the supply cabinet


2 Connection panel on robot controller
3 Equipotential bonding connection on the drive system (robot kine-
matic system)
4 Equipotential bonding from the robot controller to the drive system
5 Cable duct
6 Equipotential bonding from the start of the cable duct to the main
equipotential bonding
7 Main equipotential bonding
8 Equipotential bonding from the end of the cable duct to the main
equipotential bonding

Fig. 6-24: Equipotential bonding, robot controller - robot kinematic


system

1 PE to central PE rail of the supply cabinet


2 Connection panel on robot controller

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3 Equipotential bonding from the robot controller to the drive system
4 Equipotential bonding connection on the drive system (robot kine-
matic system)

6.11 Modifying the system configuration, exchanging devices

Description

The system configuration of the industrial robot must be configured using


WorkVisual in the following cases:
• New installation of KSS
This is the case if a KSS package is installed without KSS already be-
ing present (because it has been uninstalled or deleted or has never
been installed).
• The hard drive has been exchanged.
• A device has been replaced by a device of a different type.
• More than one device has been replaced by a device of a different
type.
• One or more devices have been removed.
• One or more devices have been added.

Exchanging devices

If a device is exchanged, at least one KCB, KSB or KEB device is re-


placed by a device of the same type. Any number of KCB, KSB and KEB
devices can be exchanged until all devices in the KCB, KSB and KEB
have been replaced simultaneously by devices of the same type. Simulta-
neous exchange of two identical components of the KCB is not possible.
Only one of the identical components may be exchanged at any one time.
The interchanging of 2 identical devices can only occur in the case of
the KSP3x40 if the current system configuration contains 2 KSP3x40.

6.12 Operator safety acknowledgement

A dual-channel acknowledge button must be installed outside the physical


safeguard. The closing of the safety gate must be confirmed by pressing
the acknowledge button before the industrial robot can be started again in
Automatic mode.

6.13 Performance level

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


Performance Level d according to EN ISO 13849-1.

6.13.1 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 E-STOP
device is 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.

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The PFH values relate to the specific safety functions of the different con-
Planning

troller variants.
Safety function groups:

• Standard safety functions


‒ Operating mode selection
‒ Operator safety
‒ EMERGENCY STOP device
‒ Enabling device
‒ External safe operational stop
‒ External safety stop 1
‒ External safety stop 2
‒ Velocity monitoring in T1
‒ Control of the peripheral contactor
• Safety functions of KUKA Safe Operation 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 C4; KR C4 CK < 1 x 10-7
KR C4 midsize; KR C4 midsize CK < 1 x 10-7
KR C4 extended; KR C4 extended CK < 1 x 10-7
KR C4 NA; KR C4 CK NA < 1 x 10-7
KR C4 NA variant: TTE1 < 1 x 10-7
KR C4 NA extended; KR C4 CK NA extended < 1 x 10-7
KR C4 variant: TBM1 < 1 x 10-7
KR C4 variants: TDA1; TDA2; TDA3; TDA4 < 1 x 10-7
KR C4 smallsize-2 variants: TDA4 < 1 x 10-7
KR C4 variants: TFO1; TFO2 < 2 x 10-7
KR C4 variants: TRE1; TRE2 < 1.7 x 10-7
KR C4 variant: TRE3 < 1 x 10-7
KR C4 variants: TVO1; TVO2; TVO3 < 1 x 10-7
VKR C4 variants: TVW1; TVW2; TVW3; TVW4, TVW5, < 1 x 10-7
TVW6
VKR C4 smallsize-2 variants: TVW1; TVW3 < 1 x 10-7
VKR C4 Retrofit
< 1 x 10-7
• Without external EMERGENCY STOP and operator
5 x 10-7
safety functions
• External EMERGENCY STOP and operator safety
functions

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Planning
Robot controller variant PFH value
KR C4 Panel Mounted < 1 x 10-7
KR C4 SC1PA passenger < 6 x 10-9
KR C4 compact < 1 x 10-7
KR C4 compact slimline < 1 x 10-7
KR C4 smallsize < 1 x 10-7
KR C4 smallsize-2 < 1 x 10-7
KR C4 smallsize-2 with KR C4 smallsize drive box < 1 x 10-7

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

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Transportation KR C4 extended

7 Transportation

7.1 Transportation using lifting tackle

Precondition

• The robot controller must be switched off.


• No cables may be connected to the robot controller.
• The door of the robot controller must be closed.
• The robot controller must be upright.
• The anti-toppling bracket must be fastened to the robot controller.

WARNING
Use of unsuitable handling equipment may result in damage to the ro-
bot controller or injury to persons. Only use authorized handling equip-
ment with a sufficient load-bearing capacity. Only transport the robot
controller in the manner specified here.

Necessary equipment

• Lifting tackle
• 4 eyebolts
Recommendation:
M10 eyebolts acc. to DIN 580 with the following properties:
‒ Screw thread: M10
‒ Material: C15E
‒ Inside/outside diameter: 25 mm/45 mm
‒ Thread length: 17 mm
‒ Pitch: 1.5 mm
‒ Load-bearing capacity: 230 kg

Procedure

1. Attach the lifting tackle with or without a lifting frame to all 4 transport
eyebolts on the robot controller.

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Transportation
Fig. 7-1: Transportation using lifting tackle

1 Transport eyebolts on the robot controller


2 Correctly attached lifting tackle
3 Correctly attached lifting tackle
4 Incorrectly attached lifting tackle

2. Attach the lifting tackle to the crane.


WARNING
If the suspended robot controller is transported too quickly, it may
swing and cause injury or damage. Transport the robot controller
slowly.

3. Slowly lift and transport the robot controller.


4. Slowly lower the robot controller at its destination.
5. Unhook lifting tackle on the robot controller.

7.2 Transportation by fork lift truck

Precondition

• The robot controller must be switched off.


• No cables may be connected to the robot controller.
• The door of the robot controller must be closed.
• The robot controller must be upright.
• The anti-toppling bracket must be fastened to the robot controller.

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WARNING
Use of unsuitable handling equipment may result in damage to the ro-
bot controller or injury to persons. Only use authorized handling equip-
ment with a sufficient load-bearing capacity. Only transport the robot
controller in the manner specified here.

Transportation with standard cabinet base

The robot controller can be picked up using a fork lift truck. The robot
controller must not be damaged when inserting the forks beneath the ro-
bot controller. After insertion, the forks of the fork lift truck must be
opened until they are in contact with the cabinet bases.

Fig. 7-2: Transportation with standard cabinet base

1 Standard cabinet base


2 Anti-toppling bracket

Transportation with fork slots

The robot controller can be picked up by fork lift truck using two fork slots
(option).
NOTICE
Avoid excessive loading of the fork slots through undue inward or out-
ward movement of hydraulically adjustable forks of the fork lift truck.
Failure to do so may result in material damage.

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Transportation
Fig. 7-3: Transportation with fork slots

1 Fork slots

Transportation with transformer

The robot controller with transformer (option) can be picked up using a


fork lift truck and lifted off the pallet. The fork lift brackets must not be
damaged when inserting the forks beneath the transformer. After insertion,
the forks of the fork lift truck must be opened until they are in contact with
the fork lift brackets.
WARNING
If the robot controller is transported over longer distances by fork lift
truck, the fork lift brackets may bend. The robot controller may then tilt
during transportation and cause personal injury or damage to property.
The robot controller with transformer must only be lifted off the pallet.
Transportation over longer distances is not permitted.

Fig. 7-4: Transportation with transformer

1 Fork lift brackets


2 Transformer

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Transportation with the set of rollers

Insert the forks of the fork lift truck between the anti-toppling bracket and
the cross-strut of the roller set.

Fig. 7-5: Transportation with the set of rollers

1 Anti-toppling bracket
2 Cross-strut of the roller set

7.3 Transportation by pallet truck

Precondition

• The robot controller must be switched off.


• No cables may be connected to the robot controller.
• The door of the robot controller must be closed.
• The robot controller must be upright.
• The anti-toppling bracket must be fastened to the robot controller.

Fig. 7-6: Transportation by pallet truck

1 Anti-toppling bracket

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Start-up and recommissioning


8 Start-up and recommissioning

8.1 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.

Electrical system

Step Description Information


1 Carry out a visual inspection of the robot -
controller.
2 Make sure that no condensation has formed -
in the robot controller.
3 Install the robot controller. (>>> 8.2 "Installing the robot
controller" Page 97)
4 Connect the connecting cables. (>>> 8.3 "Connecting the con-
necting cables" Page 98)
6 Plug in the KUKA smartPAD. (>>> 8.3.2 "Plugging in the
KUKA smartPAD" Page 99)
7 Connect the equipotential bonding between (>>> 8.5 "Connecting the PE
the manipulator and the robot controller. equipotential bonding"
Page 100)
8 Connect the robot controller to the power (>>> 8.6 "Power supply connec-
supply. tion via X1 Harting connector"
Page 100)
9 Reverse the battery discharge protection (>>> 8.7 "Reversing the battery
measures. discharge protection measures"
Page 101)
10 Drive configuration modified. (>>> 8.8 "Modifying the system
configuration, exchanging devi-
ces" Page 101)
11 Start-up mode (>>> 8.9 "Start-up mode"
Page 102)
12 Switch on the robot controller. (>>> 8.10 "Switching on the ro-
bot controller" Page 103)
13 Check the safety equipment. Detailed information is contained
in the operating and assembly in-
structions for the robot controller,
in the “Safety” chapter.
14 Configure the inputs/outputs between the ro- Detailed information can be
bot controller and the periphery. found in the field bus documen-
tation.

8.2 Installing the robot controller

Procedure

1. Install the robot controller. The minimum clearances to walls, other


cabinets, etc. must be observed.

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2. Check the robot controller for any damage caused during transporta-
tion.
3. Check that fuses, contactors and boards are fitted securely.
4. Secure any modules that have come loose.
5. Check that all screwed and clamped connections are securely fas-
tened.
6. The operator must cover the warning label Read manual with the la-
bel in the relevant local language.

8.3 Connecting the connecting cables

Overview

A cable set is supplied with the drive system. In the standard version this
consists of:
• Motor cables to the drives
• Data cable
• smartPAD with connecting cable
• Power supply cable / infeed
The following cables may be provided for additional applications:
• Peripheral cables

• The following cables may be provided for additional applications:


‒ Motor cables for external axes
‒ Peripheral cables

WARNING
The robot controller is preconfigured for the specific industrial robot. If
cables are interchanged, the manipulator and the external axes (option-
al) may receive incorrect data and can thus cause personal injury or
material damage. If a system consists of more than one manipulator, al-
ways connect the connecting cables to the manipulators and their cor-
responding robot controllers.

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).

Procedure

1. Route the motor cables to the junction box of the manipulator/motor


box/robot kinematic system separately from the data cables.
2. Route the motor cables of the external axes to the junction box of the
manipulator/motor box/robot kinematic system separately from the data
cables.
3. Route and connect the data cables to the junction box of the manipu-
lator/motor box/robot kinematic system separately from the motor ca-
ble.
4. Connect the peripheral cables.

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Fig. 8-1: Example: Installing the cables in the cable duct

1 Cable duct 4 Motor cables


2 Separating webs 5 Data cables
3 Welding cables

8.3.1 Connecting data cables X21

Procedure

• Connect data cable to X21 on the robot controller.

Connector pin allocation X21

Pin Description
2 +24 V PS1
3 GND
9 TPF0_P
10 TPFI_P
11 TPF0_N
12 TPFI_N

8.3.2 Plugging in the KUKA smartPAD

Description

The KUKA smartPAD is connected to interface X19.

Procedure

• Plug the KUKA smartPAD to X19 on the robot controller.

WARNING
If the smartPAD is disconnected, the system can no longer be switched
off by means of the EMERGENCY STOP device on the smartPAD. For
this reason, an external EMERGENCY STOP must be connected to the
robot controller.
The user is responsible for ensuring that the smartPAD is immediately
removed from the system when it has been disconnected. The smart-
PAD must be stored out of sight and reach of personnel working on the
robot. This prevents operational and non-operational EMERGENCY
STOP devices from becoming interchanged.
Failure to observe these precautions may result in death, injuries or
damage to property.

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Connector pin allocation X19

Pin Description
11 TD+
12 TD-
2 RD+
3 RD-
8 smartPAD plugged in (A) 0 V
9 smartPAD plugged in (B) 24 V
5 24 V PS2
6 GND

8.4 Fastening the KUKA smartPAD holder (optional)

Procedure

• Fasten the smartPAD holder on the door of the robot controller or on


the wall. (>>> 6.4 "Fastening the KUKA smartPAD holder (optional)"
Page 65)

8.5 Connecting the PE equipotential bonding

Procedure

1. Connect an additional 16 mm2 PE conductor between the central PE


rail of the supply cabinet and the PE bolt of the robot controller.
2. Connect a 16 mm2 cable as equipotential bonding between the manip-
ulator and the robot controller.
3. After installation of the robot system, the fault loop impedance must
be tested in accordance with EN 60204-1 Section 18.2.2, Test 2.

8.6 Power supply connection via X1 Harting connector

Description

The robot controller is connected to the mains via a Harting connector X1.
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
material damage to the power supply units. Electrical voltage can
cause injuries. The robot controller may only be operated with groun-
ded-neutral power supply systems.

Precondition

• The robot controller is switched off.


• The power cable is de-energized.

Procedure

• Connect the robot controller to the power supply via X1.

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Connector pin allocation X1

Pin Description
1 L1
2 L2
3 L3
PE PE

8.7 Reversing the battery discharge protection measures

Description

To prevent the batteries from discharging before the controller has been
started up for the first time, the robot controller is supplied with connector
X305 disconnected from the CCU.

Procedure

• Plug connector X305 into the CCU.

Fig. 8-2: Battery discharge protection X305

1 Connector X305 on the CCU

8.8 Modifying the system configuration, exchanging devices

Description

The system configuration of the industrial robot must be configured using


WorkVisual in the following cases:

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• New installation of KSS


This is the case if a KSS package is installed without KSS already be-
ing present (because it has been uninstalled or deleted or has never
been installed).
• The hard drive has been exchanged.
• A device has been replaced by a device of a different type.
• More than one device has been replaced by a device of a different
type.
• One or more devices have been removed.
• One or more devices have been added.

Exchanging devices

If a device is exchanged, at least one KCB, KSB or KEB device is re-


placed by a device of the same type. Any number of KCB, KSB and KEB
devices can be exchanged until all devices in the KCB, KSB and KEB
have been replaced simultaneously by devices of the same type. Simulta-
neous exchange of two identical components of the KCB is not possible.
Only one of the identical components may be exchanged at any one time.
The interchanging of 2 identical devices can only occur in the case of
the KSP3x40 if the current system configuration contains 2 KSP3x40.

8.9 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
• System Software 8.3:
Start-up mode is always possible. This also means that it is independ-
ent of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection
to a higher-level safety system exists or is established.

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.

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DANGER
External safeguards are disabled in Start-up mode. Observe the safety
instructions relating to Start-up mode.
(>>> 5.8.3.2 "Start-up mode" Page 54)

In Start-up mode, the system switches to the following simulated input im-
age:
• The external EMERGENCY STOP is not active.
• The safety gate is open.
• No safety stop 1 has been requested.
• No safety stop 2 has been requested.
• No safe operational stop has been requested.
If SafeOperation or SafeRangeMonitoring is used, Start-up mode also in-
fluences other signals.
Information about the effects of Start-up mode in conjunction with Safe-
Operation or SafeRangeMonitoring can be found in the documentation
SafeOperation and SafeRangeMonitoring.

Mapping of standard signals:


Byte0: 0100 1110
Byte1: 0100 0000
SafeOperation or SafeRangeMonitoring signal mapping:
Byte2: 1111 1111
Byte3: 1111 1111
Byte4: 1111 1111
Byte5: 1111 1111
Byte6: 1000 0000
Byte7: 0000 0000

8.10 Switching on the robot controller

Precondition

• The door of the robot controller is closed.


• All electrical connections are correct and the power supply is within
the specified limits.
• 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 cabinet must have adapted to the am-
bient temperature.

We recommend that all motions of the manipulator should be triggered


from outside the safety fencing.

Procedure

1. Switch on the mains power to the robot controller.


2. Release the E-STOP device on the KUKA smartPAD.
3. Switch on the main switch. The control PC begins to boot the operat-
ing system and the control software.

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9 Operation

9.1 KUKA smartPAD teach pendant

9.1.1 Front view

Function

The smartPAD is the teach pendant for the industrial robot. The smartPAD
has all the operator control and display functions required for operating
and programming the industrial robot.
The smartPAD has a touch screen: the smartHMI can be operated with a
finger or stylus. An external mouse or external keyboard is not necessary.

Overview

Fig. 9-1: KUKA smartPAD, front view

Item Description
1 Button for disconnecting the smartPAD

2 Mode selector switch. The switch may be one of the following


variants:

• With key

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Operation
Item Description
• Without key
The mode selector switch is used to call the connection man-
ager. The operating mode can be changed by using the con-
nection manager.

3 EMERGENCY STOP device Stops the robot in hazardous sit-


uations. The EMERGENCY STOP button locks itself in place
when it is pressed.
4 Space Mouse: For moving the robot manually
5 Jog keys: For moving the robot manually
6 Key for setting the program override
7 Key for setting the jog override
8 Main menu key: Shows the menu items on the smartHMI

9 Status keys. The status keys are used primarily for setting pa-
rameters in technology packages. Their exact function depends
on the technology packages installed.
10 Start key: The Start key is used to start a program.
11 Start backwards key: The Start backwards key is used to start
a program backwards. The program is executed step by step.
12 STOP key: The STOP key is used to stop a program that is
running.
13 Keyboard key
Displays the keyboard. It is generally not necessary to press
this key to display the keyboard, as the smartHMI detects
when keyboard input is required and displays the keyboard au-
tomatically.

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9.1.2 Rear view

Overview

Fig. 9-2: KUKA smartPAD, rear view

1 Enabling switch 4 USB connection


2 Start key (green) 5 Enabling switch
3 Enabling switch 6 Identification plate

Description

Element Description
Rating plate Rating plate
Start key The Start key is used to start a program.
The enabling switch has 3 positions:

• Not pressed
• Center position
Enabling • Fully pressed (panic position)
switch The enabling switch must be held in the center posi-
tion in operating modes T1 and T2 in order to be
able to jog the manipulator.
In the operating modes Automatic and Automatic Ex-
ternal, the enabling switch has no function.

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Operation
Element Description
The USB connection is used, for example, for archiv-
USB connec- ing and restoring data.
tion
Only for FAT32-formatted USB sticks.

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Maintenance KR C4 extended

10 Maintenance
Description

Maintenance work must be performed at the specified maintenance inter-


vals after commissioning at the customer’s plant.

10.1 Maintenance symbols

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

Exchanging the toothed belt

Check toothed belt tension

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• The power cable is de-energized.


• Observe the ESD guidelines.

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Maintenance
Fig. 10-1: Maintenance points

Interval Item Activity


1 year at 5 Depending on installation conditions and degree of
the latest fouling, clean the protective grille of the external
fan with a brush.
2 years at 1 Depending on installation conditions and degree of
the latest fouling, clean the heat exchanger with a brush.
2, Depending on installation conditions and degree of
10 fouling, clean the internal fans with a brush.
4 Depending on installation conditions and degree of
fouling, clean the heat sinks of the KPP, KSPs
and low-voltage power supply with a brush.
5 Depending on installation conditions and degree of
fouling, clean the external fan with a brush.
5 years 6 Exchange the motherboard battery.
5 years 3 Exchange the control PC fan. (>>> 11.4.2 "Ex-
(with 3- changing the control PC fan" Page 115)
shift oper- 5 Exchange the external fan. (>>> 11.2 "Exchanging
ation) the external fan" Page 111)
2 Exchange the internal fan
As indica- 9 Exchange the batteries.
ted by the

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Interval Item Activity


battery
monitoring
When 7 Depends on installation conditions and degree of
pressure fouling. Visual inspection of the pressure relief
relief plug plug: change filter insert if discolored (original col-
becomes or: white) (>>> 11.8 "Exchanging the pressure re-
discolored lief plug" Page 133)
Once an activity from the maintenance list has been carried out, a visual
inspection must be made, with special attention to the following points:
• Check that fuses, contactors, plug-in connections and boards are fitted
securely.
• Check cabling for damage.
• Check PE equipotential bonding connection.
• Check all system components for wear and damage.

10.2 Cleaning the robot controller

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The controller has been shut down.
• The power cable is de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• 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
11 Repair

11.1 Repair and procurement of spare parts

Repair

Repairs to the robot controller may only be carried out by KUKA customer
support personnel or by customers who have taken part in a relevant
course of training held by KUKA Deutschland GmbH.
Repairs within modules may only be carried out by specially trained KUKA
Deutschland GmbH personnel.

Procurement of spare parts

The article numbers of the spare parts are listed in the spare parts cata-
log.
KUKA Deutschland GmbH supplies the following types of spare parts for
repairs to the robot controller:
• New parts
Once the new part has been installed, the part that has been removed
can be disposed of.
• Exchange parts
Once the exchange part has been installed, the part that has been re-
moved is returned to KUKA Deutschland GmbH.

A “Robot Repair Card” is supplied with the exchange parts. The Repair
Card must be completed and returned to KUKA Deutschland GmbH.

11.2 Exchanging the external fan

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

Procedure

1. Unplug fan connector X14 on the CCU.


2. Remove the rear panel.

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Fig. 11-1: Exchanging the external fan

1 Fastening of rear panel


2 Fan connector X14 on the CCU

3. Remove the screws of the cable inlet.


4. Swivel back the cable inlet and pull out the connecting cable.

Fig. 11-2: External fan, cable inlet

1 Fastening of cable inlet


2 Cover of the cable inlet

5. Remove the fan holder together with the fan.


6. Install the new fan together with its holder and fasten.

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Repair
Fig. 11-3: Exchanging the external fan

1 Fastening of the fan holder

7. Route the connecting cable in the cabinet.


8. Mount the cable inlet.
9. Insert and fasten the rear panel
10. Plug in fan connector X14 on the CCU.

11.3 Exchanging the internal fan

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

Description

The internal fan is not installed in all cabinet variants. As as alternative to


the internal fan, a KPC cooling duct may be installed. The internal fan is
located in the lower left-hand corner of the control cabinet.

Procedure

1. Unplug fan connector X962 from the fan module.

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Fig. 11-4: Removing the fan module

1 Fastening screw 2 Connector X962

2. Loosen the fastening screw of the fan module.


3. Take off fan module.
4. Insert the new fan module and fasten it with the fastening screw.
5. Plug fan connector X962 into the fan module.

11.4 Exchanging control PC components

11.4.1 Exchanging the control PC

Precondition

• Observe the ESD guidelines.


• From KSS 8.3 and from motherboard D3236-K onwards:
‒ Board Package USB stick in the USB port.

Procedure

1. Shut down the robot controller with the settings Cold start and Re-
load files.
2. Turn off the robot controller using the main switch and take measures
to prevent it from being turned on again unintentionally.
3. Disconnect the power cable from the supply.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

4. Unplug the power supply and all connections to the control PC.
5. Slacken the knurled nuts.
6. Remove the control PC and lift it out towards the top.

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Repair
Fig. 11-5: Fastening elements of the control PC

1 Knurled nut
2 Tilt the PC
3 Lift the PC
3b Rail

7. Insert the new control PC and fasten.


8. Plug in the connections.
For network cable connection, see
9. Switch on the robot controller.
From KSS 8.3 and from motherboard D3236-K onwards:
• Once the controller has been successfully started, disconnect the
Board Package USB stick and carefully store it.
Starting and installing the drivers may take some time.

11.4.2 Exchanging the control PC fan

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

Procedure

1. Remove the control PC. (>>> 11.4.1 "Exchanging the control PC"
Page 114)
2. Remote air duct, if present.
3. Remove the control PC cover.
4. Release and unplug the fan connector. Depending on the variant, the
fan connector is located either on the housing or directly on the moth-
erboard.

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Fig. 11-6: Disconnecting control PC fan from housing or mother-


board

1 Fan connector 4 Fan grille


2 Control PC housing 5 CPU fan
3 Fan

5. Remove outer fan grille.


6. Pull the fan inwards off the mounting plugs.
7. Remove the expanding rivets and take off the inner fan grille.

Fig. 11-7: PC fan configuration

1 Mounting plugs 4 Fan grille (optional, de-


pending on variant)
2 Outer fan grille 5 Fan identification plate
3 Fastening of fan grille (ex-
panding rivets)

8. Fasten the inner fan grille to the new fan with the expanding rivets.
The fan grille must be fastened to the side with the identification
plate. See (>>> Fig. 11-7)

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Repair
Fig. 11-8: Installing the control PC fan

1 Mounting plugs on the fan 3 Mounting plugs on the PC


housing
2 Fan grille

9. Install the mounting plugs in the fan.


10. Insert the fan into the PC housing and pull the mounting plugs through
the PC housing.
11. Reattach outer fan grille.
12. Install the air duct.

11.4.3 Exchanging the motherboard

A defective motherboard is not exchanged separately, but together with


the control PC.

11.4.4 Exchanging the motherboard battery

The battery on the motherboard of the control PC may only be exchanged


by authorized maintenance personnel in consultation with the KUKA cus-
tomer support service.

11.4.5 Exchanging the LAN Dual NIC network card

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

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Description

Depending on the control PC variant, the LAN Dual NIC network card is
permanently integrated into the motherboard. In this case, if the LAN Dual
NIC network card is defective, the entire control PC must be exchanged.
If the LAN Dual NIC network card is plugged onto the motherboard, it can
be exchanged separately.

Procedure

1. Open the PC chassis.


2. Unplug the connections to the LAN Dual NIC network card.
3. Release the fastenings of the card and pull the card out of the slot.
4. Inspect the new LAN Dual NIC network card for mechanical damage.
5. Plug the LAN Dual NIC network card into its slot and tighten the fas-
tening screw.
6. Plug in the connections to the card.

11.4.6 Exchanging the hard drive

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

Procedure

1. Slacken the knurled screws of the SSD.


2. Release and unplug the SATA connector.
3. Unplug power supply connector.
4. Remove the hard drive and replace it with a new one.
5. Plug in the SATA and power supply connectors.
6. Fasten the hard drive with the knurled screws.
7. Install the operating system and the KUKA System Software (KSS).
8. The system setup of the robot must be configured using WorkVisual.
Once the hard drive has been exchanged, the following options are
available in addition to configuration using WorkVisual:
‒ Load the archive of the previous installation.
‒ Restore the complete image using the KUKA Recovery Tool.

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Repair
Fig. 11-9: Exchanging the hard drive

1 SATA connector
2 Power supply connector
3 Knurled screws on the underside

11.5 Modifying the system configuration, exchanging devices

Description

The system configuration of the industrial robot must be configured using


WorkVisual in the following cases:
• New installation of KSS
This is the case if a KSS package is installed without KSS already be-
ing present (because it has been uninstalled or deleted or has never
been installed).
• The hard drive has been exchanged.
• A device has been replaced by a device of a different type.
• More than one device has been replaced by a device of a different
type.
• One or more devices have been removed.
• One or more devices have been added.

Exchanging devices

If a device is exchanged, at least one KCB, KSB or KEB device is re-


placed by a device of the same type. Any number of KCB, KSB and KEB
devices can be exchanged until all devices in the KCB, KSB and KEB
have been replaced simultaneously by devices of the same type. Simulta-
neous exchange of two identical components of the KCB is not possible.
Only one of the identical components may be exchanged at any one time.
The interchanging of 2 identical devices can only occur in the case of
the KSP3x40 if the current system configuration contains 2 KSP3x40.

11.5.1 Exchanging the KUKA Power Pack

Precondition

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

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CAUTION
If removal is performed immediately after the robot controller has
been shut down, the heat sink surface temperatures are likely to be
high and could result in burn injuries. Protective gloves must be
worn.

• The power cable is de-energized.


WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.


• Wait 5 minutes until the intermediate circuit has discharged.
WARNING
The following components may remain energized (50-780 V) up to
5 minutes after the robot controller has been switched off:
‒ the KPP
‒ the KSPs
‒ connections for motor connectors X20, X21.1, X20.4 and con-
nected motor cables
‒ the intermediate circuit connecting cables
This voltage can cause life-threatening injuries.

KPP 3 connections

Fig. 11-10: KPP 3 connections

Item Connector Description


1 X30 Brakes power supply OUT
2 X20 Drive bus OUT
3 X10 Control electronics power supply OUT
4 X7 Ballast resistor

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Item Connector Description
5 X6 DC link OUT
6 X11 Control electronics power supply IN
7 X21 Drive bus IN
8 X34 Brakes power supply IN
9 X3 Motor connection 3
10 X33 Connection, brake 3
11 X32 Connection, brake 2
12 X2 Motor connection 2
13 X1 Motor connection 1
14 X31 Connection, brake 1
15 X4 AC power supply connection and PE

Procedure

1. Unlock connectors X20 and X21 of the data cables. Unplug all con-
nections to the KPP.
NOTICE
Unplugging the data cable connectors without first unlocking them
damages the connectors. Unlock the connectors before unplugging
them.

Fig. 11-11: Unlocking connectors X20 and X21

1 Connector unlocked 3 Connector plugged in and


locked
2 Connector locked 4 Connector plugged in and
unlocked

2. Slacken the Allen screws.


CAUTION
The KPP weighs approx. 10 kg. When removing or installing the
KPP, care must be taken to avoid injury by crushing. Protective
gloves must be worn.

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3. Lift the KPP slightly, tilt the top forwards and lift the KPP out of the
support bracket.
4. Insert the new KPP into the support bracket, hook it on at the top and
tighten the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable
labeling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
setup of the robot must be configured using WorkVisual.

Fig. 11-12: KPP fastening

1 Allen screws 3 Support bracket


2 Rear panel of cabinet

11.5.2 Exchanging the KUKA Servo Pack

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
CAUTION
If removal is performed immediately after the robot controller has
been shut down, the heat sink surface temperatures are likely to be
high and could result in burn injuries. Protective gloves must be
worn.

• The power cable is de-energized.


WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.


• Wait 5 minutes until the intermediate circuit has discharged.

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WARNING
The following components may remain energized (50-780 V) up to
5 minutes after the robot controller has been switched off:
‒ the KPP
‒ the KSPs
‒ connections for motor connectors X20, X21.1, X20.4 and con-
nected motor cables
‒ the intermediate circuit connecting cables
This voltage can cause life-threatening injuries.

Connections

Fig. 11-13: KSP connection with amplifiers for 3 axes

Item Connector Description


1 X30 Brakes power supply OUT
2 X20 Drive bus OUT
3 X10 Control electronics power supply OUT
4 X5 DC link OUT
5 X6 DC link IN
6 X11 Control electronics power supply IN
7 X21 Drive bus IN
8 X34 Brakes power supply IN
9 X3 Motor connection 3
10 X33 Connection, brake 3
11 X32 Connection, brake 2
12 X2 Motor connection 2
13 X31 Connection, brake 1
14 X1 Motor connection 1

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Procedure

1. Unlock connectors X20 and X21 of the data cables. Unplug all con-
nections to the KSP.
NOTICE
Unplugging the data cable connectors without first unlocking them
damages the connectors. Unlock the connectors before unplugging
them.

Fig. 11-14: Unlocking connectors X20 and X21

1 Connector unlocked 3 Connector X21 plugged in


and locked
2 Connector locked 4 Connector X20 plugged in
and unlocked

2. Slacken the Allen screws.


CAUTION
The KSP weighs approx. 10 kg. When removing or installing the
KSP, care must be taken to avoid injury by crushing. Protective
gloves must be worn.

3. Lift the KSP slightly, tilt the top forwards and lift the KSP out of the
support bracket.
4. Insert the new KSP into the support bracket, hook it on at the top and
tighten the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable
labeling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
setup of the robot must be configured using WorkVisual.

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Fig. 11-15: KSP fastening

1 Allen screws 3 Support bracket


2 Rear panel of cabinet

11.5.3 Exchanging the Cabinet Control Unit

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable is de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.


• Wait 5 minutes until the intermediate circuit has discharged.
WARNING
The following components may remain energized (50-780 V) up to
5 minutes after the robot controller has been switched off:
‒ the KPP
‒ the KSPs
‒ connections for motor connectors X20, X21.1, X20.4 and con-
nected motor cables
‒ the intermediate circuit connecting cables
This voltage can cause life-threatening injuries.

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Repair KR C4 extended

Connections

Fig. 11-16: Connections on the CCU

Con-
Item Description
nector
1 X14 External fan connection
2 X308 External power supply, safety circuit
3 X1700 Board connection
4 X306 smartPAD power supply
5 X302 SIB power supply
6 X3 KPP1 power supply
7 X29 EDS connection, memory card
8 X30 Ballast resistor temperature monitoring
9 X309 Main contactor 1 (HSn, HSRn)
10 X312 Main contactor 2 (HSn, HSRn)
11 X310 Spare (safe input 2/3, safe output 2/3)
12 X48 Safety Interface Board SIB (orange)
13 X31 Controller bus, KPC (blue)
14 X32 Controller bus, KPP (white)
15 X311 Safe inputs, ZSE1, ZSE2; NHS (jumper plug)
16 X28 Mastering test
17 X43 KUKA Service Interface (KSI) (green)
18 X42 KUKA Operator Panel Interface smartPAD (yellow)
19 X41 KUKA System Bus, KPC (red)
20 X44 EtherCAT Interface (KUKA Extension Bus) (red)
21 X47 Spare (yellow)
22 X46 KUKA System Bus, RoboTeam (green)
23 X45 KUKA System Bus, RoboTeam (orange)

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Con-
Item Description
nector
24 X34 Controller bus, RDC (blue)
25 X33 Controller bus, spare (white)
26 X25 Fast Measurement inputs 7 ... 8
27 X23 Fast Measurement inputs 1 ... 6
28 X11 Alarm contact for main switch
29 X26 Thermostatic switch for transformer
30 X27 Alarm contact for cooling unit
31 X5 KPP2 power supply
32 X22 Options power supply
33 X4 KPC, KPP, internal fan power supply
34 X307 CSP power supply
35 X12 USB
36 X15 Internal cabinet fan (optional)
37 X1 Infeed from low-voltage power supply
38 X301 24 V without battery backup (F301)
39 X6 24 V without battery backup (F6)
40 X305 Battery
41 X21 RDC power supply

Procedure

1. Unlock the data cable connectors. Unplug all connections to the CCU.
NOTICE
Unplugging the data cable connectors without first unlocking them
damages the connectors. Unlock the connectors before unplugging
them.

Fig. 11-17: Unlocking the data cable connectors

1 Connector unlocked 3 Connector plugged in and


locked
2 Connector locked

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2. Remove the screw on the fastening plate and pull the plate with the
CCU out of the tab slots.
3. Check the new CCU for mechanical damage. Insert the fastening plate
with the CCU into the tab slots and screw it firmly in place.
4. Plug in all the connections in accordance with the connector and cable
labeling. Lock the data cable connectors.

Fig. 11-18: CCU fastening

1 Tabs
2 Fastening screw

11.5.4 Exchanging the Resolver Digital Converter

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

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Connections

Fig. 11-19: Overview of RDC connections

Connect-
Item Description
or
1 X1 Resolver connection, axis 1
2 X2 Resolver connection, axis 2
3 X3 Resolver connection, axis 3
4 X4 Resolver connection, axis 4
5 X5 Resolver connection, axis 5
6 X6 Resolver connection, axis 6
7 X7 Resolver connection, axis 7
8 X8 Resolver connection, axis 8
9 X13 EDS connection, memory card, RDC
10 X20 EMD
11 X19 KCB OUT
12 X18 KCB IN
13 X17 EMD power supply
14 X15 Power supply IN
15 X16 Power supply OUT (next KCB device)

Procedure

1. Remove the screws from the lid of the RDC box.

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Fig. 11-20: RDC box connections

1 Union for 2 external axis control cables X7 and X8


2 Bolt for ground conductor connection
3 Data cable X31
4 EMD connection X32
5 Cable inlet for resolver connections X1-X6

2. Carefully disconnect all cables and bend them out of the way to the
sides.
3. Carefully unplug the EDS connection.
The EDS memory is not removed and remains in the RDC box
when the RDC is exchanged.

4. Remove the fastening screws of the RDC module.

Fig. 11-21: RDC fastening

1 Fastening the RDC module: M6x10


Tightening torque: 2.0 Nm
2 Fastening the EDS: M2.5 plastic nuts
Tightening torque: 0.1 Ncm

5. Carefully remove the RDC module from the RDC box without tilting it.
6. Insert and fasten the new RDC module.
7. Connect all cables.
8. Plug in the EDS connection.

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9. Close the lid of the RDC box and screw it firmly in place.

11.6 Exchanging the batteries in the cabinet door

Precondition

• Robot controller is shut down.


• The robot controller is switched off and secured to prevent unauthor-
ized persons from switching it on again.
• The power cable is de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

Procedure

1. Unplug the battery connection cables.


WARNING
A short-circuit or short to ground at the battery poles causes a very
high short-circuit current. This short-circuit current can cause severe
injury and substantial damage to property. It must be ensured that
no short-circuit or short to ground is caused at the battery poles.

WARNING
A short-circuit or short to ground at the battery poles can trip the
higher-level fuse. The batteries have no fuse of their own. It must
be ensured that no short-circuit or short to ground is caused at the
battery poles.

2. Remove both battery blocks from the battery holder in the cabinet
door.
The battery blocks must both be exchanged together.

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Repair KR C4 extended

Fig. 11-22: Battery fastening

3. Insert the new battery blocks and plug in the battery connection ca-
bles.

Fig. 11-23: Battery polarity

WARNING
Observe the illustrated battery polarity. Installing the batteries in the
wrong position or with reversed polarity can generate a high short-
circuit current and trip the higher-level fuse.

11.7 Exchanging the low-voltage power supply unit

Precondition

• Robot controller is shut down.


• The robot controller is switched off and secured to prevent unauthor-
ized persons from switching it on again.
• The power cable is de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

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Procedure

1. Remove the rear panel.


2. Unplug the connections.
3. Loosen the fastening screws.
4. Tilt the low-voltage power supply unit forward and lift it out vertically.

Fig. 11-24: Low-voltage power supply

1 Power supply connector X2 4 Fastening screws


2 CCU power infeed connec- 5 Low-voltage power supply
tor X1 unit removed
3 XPE connector

5. Insert and fasten the new low-voltage power supply unit.


6. Plug in the connectors; insert and fasten the rear panel.

11.8 Exchanging the pressure relief plug

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

Description

The pressure relief plug is used to generate an overpressure inside the


cabinet. This prevents excessive fouling of the cabinet.

Procedure

1. Remove the foam ring.

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2. Exchange the filter insert.


3. Insert the foam ring so that it is flush with the pressure relief plug.

Fig. 11-25: Exchanging the pressure relief plug

1 Pressure relief plug 3 Foam ring


2 Filter insert

11.9 Exchanging the mains filter

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

Procedure

1. Disconnect the mains filter from main switch Q1 and power circuit-
breaker Q3

Fig. 11-26: Disconnecting the mains filter cables

1 Q1 cable wires
2 Q3 cable wires

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2. Unscrew the fastening nuts on the mains filter cable to Q1 and Q3 on
the inside of the cabinet.

Fig. 11-27: Removing the mains filter cables

1 Q1 supply cable, main switch


2 Q3 supply cable, power circuit breaker

3. Unscrew the nut on the inside of the control cabinet.

Fig. 11-28: Nut on mains filter side panel, bottom

1 Fastening bolt

4. Unscrew the side panel fastening screws and take off the side panel.

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Fig. 11-29: Removing the side panel

1 Fastening screws

5. Remove the ground conductor from the mains filter.

Fig. 11-30: Removing the ground conductor

1 Ground cable fastening

6. Remove the mains filter.


7. Insert the new mains filter and fasten.
8. Connect the wire ends of the mains filter cables to Q1 and Q3 in ac-
cordance with the wiring diagram.
9. Insert and close the side panel and fasten it with a nut on the threa-
ded bolt.
10. Carry out a function test.

11.10 Exchanging the KEB inverter

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

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Repair
• Observe the ESD guidelines.

Procedure

1. Unplug the connections.


2. Unscrew the supply lines, brake resistor, PE and motor cables.
3. Remove the fastening screws from the shield plate.
4. Take out the KEB inverter and shield plate.
5. Remove the KEB inverter from the shield plate.
6. Mount the new KEB inverter on the shield plate. If necessary, replace
the IP54 seal with a new one.
7. Insert the KEB inverter and shield plate.
8. Screw on the supply lines, brake resistor, PE and motor cables.

Fig. 11-31

1 PE connection
2 Power cables
3 Brake resistor
4 Motor cables

9. Plug in the connections.

11.11 Exchanging the KEB mains filter

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

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Procedure

1. Unplug the connections.

Fig. 11-32: Connections

1 PE connection
2 Plug-in connections

2. Unscrew the fastener and take off the mains filter.


3. Insert the new mains filter and fasten.
4. Plug in the connections.

11.12 Exchanging the KEB brake resistor

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The power cable must be de-energized.
WARNING
Cables routed from power supply connection X1 to the main switch
are energized even when the main switch is switched off! This
mains voltage can cause injuries on contact.

• Observe the ESD guidelines.

Procedure

1. Remove the rear panel of the controller.


2. Remove the ground screw and fastening screws.
3. Remove the brake resistor and insert the new brake resistor.
4. Attach the ground screw and fastening screws.

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5. Mount the rear panel of the controller.

11.13 Installing the KUKA System Software (KSS)

Further information is contained in the operating and programming in-


structions for the KUKA System Software (KSS).

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Troubleshooting KR C4 extended

12 Troubleshooting

12.1 Cabinet Control Unit LED display

Overview

Fig. 12-1: CCU LED display

Item Designation Color Description Remedy


1 Fuse LEDs Red On = fuse defective Exchange defective fuse
The LEDs in- Off = fuse OK -
dicate the
status of the
fuses.
2 PWRS/3.3V Green On = power supply present -
Off = no supply voltage • Check fuse F17.3
present
• If the LED PWR/3.3V
lights up, exchange the
CCU module
3 STAS2 Orange Off = no supply voltage • Check fuse F17.3
present
Safety node • If the LED PWR/3.3V
B lights up, exchange the
CCU module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Check cabling at X309,
nal) X310, X312. For test pur-
poses, disconnect the ca-
bles at X309, X310, X312
and switch the controller
off and back on again. If

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Troubleshooting
Item Designation Color Description Remedy
the error recurs, exchange
the module.
4 STAS1 Orange Off = no supply voltage • Check fuse F17.3
present
Safety node • If the LED PWR/3.3V
A lights up, exchange the
CCU module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Check cabling at X309,
nal) X310, X312. For test pur-
poses, disconnect the ca-
bles at X309, X310, X312
and switch the controller
off and back on again. If
the error recurs, exchange
the module.
5 FSoE Green Off = not active -
Safety proto- On = operational -
col of the Flashing = fault code (inter- -
EtherCat con- nal)
nection
6 27 V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V)
Voltage, main
power supply On = power supply present -
unit, without
battery back-
up
7 PS1 Green Off = no supply voltage • Check infeed at X1
present (rated voltage 27.1 V)
Voltage, Pow-
er Supply 1 • Drive bus switched off
(short battery (BusPowerOff state)
backup) On = power supply present -
8 PS2 Green Off = no supply voltage • Check infeed at X1.
present
Voltage, Pow- • Controller in Sleep
er Supply 2 state
(medium bat- On = power supply present -
tery backup)
9 PS3 Green Off = no supply voltage Check infeed at X1.
present
Voltage, Pow-
er Supply 3 On = power supply present -
(long battery
backup)
10 L/A Green • On = physical connec- -
KSB (SIB) tion. Network cable
plugged in
L/A Green
• Off = no physical con-
KCB (KPC) nection. Network cable
L/A Green not plugged in

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Troubleshooting KR C4 extended

Item Designation Color Description Remedy


KCB (KPP) • Flashing = data traffic
11 L/A Green on the line
L/A Green
L/A Green
12 L/A Green
L/A Green
L/A Green
13 PWR/3.3V Green Off = no supply voltage • Check fuse F17.3
present
Power for the • Jumper plug X308
CIB present
• Check fuse F308
• With external supply
via X308: check the ex-
ternal power supply
(rated voltage 24 V)
On = supply voltage -
present
14 L/A Green • On = physical connec- -
L/A Green tion
L/A Green • Off = no physical con-
nection. Network cable
not plugged in.
• Flashing = data traffic
on the line
15 STA1 (CIB) Orange Off = no supply voltage • Check fuse F17.3
present
μC I/O node • If the LED PWR/3.3V
lights up, exchange the
CCU module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU module
nal)
16 STA1 (PMB) Orange Off = no supply voltage • Check infeed at X1
present
μC USB • If the LED PWR/5V
lights up, exchange the
CCU module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU module
nal)
17 PWR/5V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V)
Power supply
for PMB Flashing at 1 Hz = normal -
state

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Troubleshooting
Item Designation Color Description Remedy
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- -
nal)
18 STA2 Orange Off = no supply voltage • Check infeed at X1
present
FPGA node • If the LED PWR/3.3V
lights up, exchange the
CCU module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU module
nal)
19 RUN SION Green On = operational (normal -
state)
EtherCat
Safety nodes Off = Init (after switching -
on)
Flashing at 2.5 Hz = Pre- -
Op (intermediate state on
startup)
Single signal = Safe Op -
Flashing at 10 Hz = boot -
(for firmware update)
20 RUN CIB Green On = operational (normal -
state)
EtherCat
ATμC I/O Off = Init (after switching -
node on)
Flashing at 2.5 Hz = Pre- -
Op (intermediate state on
startup)
Single signal = Safe Op -
10 Hz = boot (for firmware -
update)

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Troubleshooting KR C4 extended

12.2 Cabinet Control Unit fusing

Overview

Fig. 12-2: Arrangement of the fuses

A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.

Item Designation Description Fusing


1 F17.1 Contactor outputs 1 … 4 CCU 5 A
2 F17.2 CCU inputs 2 A
3 F17.4 CCU safe inputs 2 A
4 F17.3 CCU logic 2 A
5 F306 smartPAD power supply 2 A
6 F302 SIB power supply 5 A

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Troubleshooting
Item Designation Description Fusing
7 F3.2 KPP1 logic with battery back- 7.5 A
up
8 F3.1 KPP1 brakes without battery 15 A
backup
9 F5.2 KPP2 logic without battery 7.5 A
backup/switch
10 F5.1 KPP2 brakes without battery 15 A
backup
11 F22 Options power supply with 7.5 A
battery backup
12 F4.1 KPC with battery backup 10 A
13 F4.2 KPC fan/internal fan with bat- 2 A
tery backup
14 F307 CSP power supply 2 A
15 F21 RDC power supply 2 A
16 F305 Battery infeed 15 A
17 F6 24 V without battery backup 7.5 A
US1 (optional)
18 F301 24 V without battery backup, 10 A
spare, US2
19 F15 Internal fan (optional) 2 A
20 F14 External fan 7.5 A
21 F308 Internal power supply, 7.5 A
external infeed with battery
backup

12.3 Resolver Digital Converter LED display

Overview

Fig. 12-3: RDC LED display

Item Designation Color Description


1 STA3 Yellow • Off = fault
• Flashing at 1 Hz = normal state

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Troubleshooting KR C4 extended

Item Designation Color Description


Motor temperature mi- • Flashing = fault code (internal)
crocontroller
2 RUN Green • Off = Init
EtherCAT AT bus • On = normal state
• Flashing at 2.5 Hz = Pre-Op
• Single signal = Safe Op
• Flashing = fault code (internal)
• Flashing at 10 Hz = boot
3 L/A1 Green • Off = no physical connection. Network
Input of the KCB (X18) cable not plugged in.
• On = network cable plugged in
• Flashing = data traffic on the line
4 L/A2 Green • Off = no physical connection. Network
Output of the KCB (X19) cable not plugged in.
• On = network cable plugged in
• Flashing = data traffic on the line
5 L/A3 Green • Off = no physical connection. Network
Output of the KCB to cable not plugged in.
the EMD (X20) • On = network cable plugged in
• Flashing = data traffic on the line
6 STA4 Yellow • Off = fault
VMT microcontroller • Flashing at 1 Hz = normal state
• Flashing = fault code (internal)
7 PWR/3.3V Green • Off = no power
RDC power supply • On = power supply connected
8 FSoE Green • Off = not active
Safety protocol of the • On = operational
EtherCat connection • Flashing = fault code (internal)
9 STA2 Yellow • Off = fault
FPGA B integrated cir- • Flashing at 1 Hz = normal state
cuit • Flashing = fault code (internal)
10 STA1 Yellow • Off = fault
FPGA A integrated cir- • Flashing at 1 Hz = normal state
cuit • Flashing = fault code (internal)
11 STA0 Yellow • Off = fault
Configuration microcon- • Flashing at 1 Hz = normal state
troller • Flashing = fault code (internal)

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KR C4 extended

Troubleshooting
12.4 Controller System Panel LED display

Overview

Fig. 12-4

Item Designation Description


1 LED1 Operating LED
2 LED2 Sleep LED
3 LED3 Automatic LED
4 LED4 Error LED
5 LED5 Error LED
6 LED6 Error LED

Controller state

Display Description State


LED1 flashes slowly Controller boots
LED2...LED6 = off
Main switch = on
LED1 flashes slowly HMI not yet loaded
and/or RTS not
LED2...LED6 = off
"RUNNING"
Main switch = on
PM service started
LED1 = on SM in "Running"
state, HMI and Cross
LED3 = any
running
LED2; LED4...LED6 =
off
Booting completed,
no error
LED1 = on Controller does not
yet shut down
LED3 = any
LED2; LED4...LED6 =
off
Main switch = off
Powerfail timeout not
yet occurred
LED1 flashes slowly Controller shuts down
LED2...LED6 = off

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Troubleshooting KR C4 extended

Display Description State


Main switch = off
Powerfail timeout has
occurred
LED1 flashes slowly Controller shuts down
LED2...LED6 = off
SoftPowerDown

CSP test

Display Description
If all LEDs light up for 3 s after the CSP is switched
on, it is working correctly

Automatic mode

Display Description
LED1 = on
LED3 = on
Controller is in Automatic mode
LED1 = on
Controller is not in Automatic mode

Sleep mode

Display Description
LED2 flashes slowly
Controller is in Sleep mode.
LED1 flashes slowly
Controller is coming out of Sleep mode.

ProfiNet ping

Display Description
LED1 = on
LED4 flashes slowly
LED5 flashes slowly
LED6 flashes slowly
ProfiNet ping is being executed

Maintenance

Display Description
LED1 = on
LED4 flashes slowly
LED2; LED3; LED5; LED6 = off
Maintenance mode active (robot controller mainte-
nance due)

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KR C4 extended

Troubleshooting
12.4.1 Controller System Panel LED error display

Error states

Display Description Remedy


LED1 flashes slowly • Check the
LED4 = on HDD/SSD
• Check the USB
Problem with boot de-
stick
vice or BIOS error
• Exchange the PC
LED1 flashes slowly • Exchange the
LED5 = on hard drive
• Reload the image
Timeout booting Win-
dows or starting the
PMS
LED1 flashes slowly • Reload the image
LED6 = on • Run setup
Timeout waiting for
RTS “RUNNING”
LED1 flashes slowly -
Timeout waiting for
HMI Ready

12.5 LAN Onboard LED display on motherboard D3445-K

Overview

Fig. 12-5: LAN Onboard LED display

Item Designation Color Description


1 Activity/Link Green • Off = no connection
• On = connection establish-
ed

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Troubleshooting KR C4 extended

Item Designation Color Description


• Flashing = connection ac-
tive
2 Speed Yellow/ • Off = 10 Mb
green
• Green = 100 Mb
• Yellow = 1000 Mb

12.6 Checking the KUKA Servo Pack

Description

The KSP LED display consists of the following LED groups:


• KSP device status
• Axis control
• Communication status
If faults occur during the initialization phase, the middle axis control LEDs
flash. All other LEDs are off. The red axis control LED is lit continuously
and the green axis control LED flashes at 2 to 16 Hz, followed by a
pause.
If defective firmware is detected during the initialization phase, the red de-
vice status LED is lit and the green device status LED is dimmed.

Precondition

WARNING
The robot controller is energized (50-600 V) when it is switched on.
This voltage can cause life-threatening injuries on contact. Work and
measurements on the electrical equipment may only be carried out by
specially trained personnel.

Procedure

1. Check communication status LED group.


2. Check KSP device status LED group.
3. Check axis control LED group.

Overview

Fig. 12-6: KSP LED display

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Troubleshooting
1 LED group: axis control 3 LED group: communication
status
2 LED group: KSP device sta-
tus

Device status

Red LED Green LED Meaning


Off Off No power supply to the control
electronics
On Off Fault in the KSP
Off Flashing No communication with the con-
troller
Off On Communication with the controller

Axis control

Red LED Green LED Meaning


Off Off No power supply to the control
electronics
Axis not present
On Off Fault in the axis
Off Flashing No servo enable
Off On Servo enable

Communication

The green communication LEDs indicate the status of the bus connection.

12.7 Checking the KUKA Power Pack 3

Description

The LED display on the KPP indicates the communication status of the
bus connection.

Precondition

WARNING
The robot controller is energized (50-600 V) when it is switched on.
This voltage can cause life-threatening injuries on contact. Work and
measurements on the electrical equipment may only be carried out by
specially trained personnel.

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Troubleshooting KR C4 extended

Overview

Fig. 12-7: KPP 3x20 A LED display

1 LED group: communication status

Communication

The green communication LEDs indicate the status of the bus connection:
LED Description
On Connected, no data transfer
Flashing Connected, data transfer
Off No connection

12.8 KPP and KSP error messages

Description

The error messages have corresponding acknowledgement messages.


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

Error no. Error Cause Remedy


26030 Device state: OK - -
26031 Internal error, The device has detec- • Reinitialize the drive bus:
KPP/KSP (axis) ted an internal error. Power Off / Power On
• Check KPP (see LEDs)
26032 IxT overload er- Axis overloaded • During start-up => excessive
ror, KPP/KSP load in program
Mean continuous cur-
(axis) rent too high • Reinitialize the drive bus:
Power Power Off / Power On
• During operation
Excessive load
‒ Modifications to system
‒ Check machine

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Troubleshooting
Error no. Error Cause Remedy
‒ Temperature influences
• Check trace recording of ax-
is/current
• Adapt program velocity
• Check CBS pressure
• Check gear unit
26033 Ground fault, Power unit overcurrent • Check motor cable
KPP/KSP (axis) (ground fault)
• Check motor
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26034 Overcurrent, Fault that briefly re- • Check trace recording of ax-
KPP/KSP (axis) sults in an overcurrent is/current
that exceeds the max-
• Check motor
imum current of the
KPP (short-circuit,…) • Check motor cable
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26035 Intermediate cir- Overvoltage in inter- • Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
high, KPP/KSP operation
• Check mains voltage
(axis)
• Check ballast switch
• Excessive load during brak-
ing => reduce
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26036 Intermediate cir- Undervoltage in inter- • Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
low, KPP/KSP operation
• Check mains voltage
(axis)
• Check intermediate circuit
cabling
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP charging circuit
26037 Logic supply volt- Overvoltage in 27 V • Check 27 V supply
age too high, supply
• Check power supply to 27 V
KPP/KSP (axis)
power supply unit
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP

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Troubleshooting KR C4 extended

Error no. Error Cause Remedy


26038 Logic supply volt- Undervoltage in 27 V • Check 27 V supply
age too low, supply
• Check power supply to 27 V
KPP/KSP (axis)
power supply unit
• Check battery
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26039 Device tempera- Overtemperature • Check cabinet fan
ture too high,
• Check ambient temperature
KPP/KSP (axis)
• Load in program too high,
check load
• Dirt in cooling circuit =>
clean
• Check PC fan
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26040 Heat sink tem- Overtemperature, heat • Check cabinet fan
perature too sink
• Check ambient temperature
high, KPP/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
• Check KSP
• Check KPP
26041 Motor phase fail- Failure of motor phase • Check motor cable
ure, KPP/KSP
• Check motor
(axis)
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
26042 Communication Communication error • Reinitialize the drive bus:
error, KPP/KSP on the controller bus Power Off / Power On
(axis)
• Check EtherCat cabling
• Check EtherCat stack
• Check CCU
• Check KPP
• Check KSP
26043 Unknown status Software error, Ether- -
flag received, Cat master
KPP/KSP (axis)

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KR C4 extended

Troubleshooting
Error no. Error Cause Remedy
26044 Unknown device - -
status, KPP/KSP
(axis)
26045 Hardware fault, The device has detec- • Reinitialize the drive bus:
KPP/KSP (axis) ted an internal hard- Power Off / Power On
ware fault.
• Check device (see LEDs)
• Exchange device
26046 Mains phase fail- Failure of mains • Check power lead
ure, KPP/KSP phase
• Check KPP cabling
(axis)
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26047 Power supply Failure, supply voltage • Check power lead
failure, KPP/KSP below 300 V
• Check KPP cabling
(axis)
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26048 Overvoltage dur- - • Mains voltage too high
ing charging,
• Too few capacitors connec-
KPP/KSP (axis)
ted (too few modules)
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26050 Fault in brake re- KPP has detected an • Check ballast resistor
sistor, KPP/KSP error in the ballast cir-
• Check cabling between KPP
(axis) cuit
and ballast resistor
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26051 Ballast circuit Braking energy per- • Reduce heavy loads that are
overload, manently too high braked too frequently
KPP/KSP (axis)
• Check ballast resistor
• Check cabling between KPP
and ballast resistor
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26130 Intermediate cir- - • Check intermediate circuit
cuit charging cabling
failed, KPP/KSP
• Reinitialize the drive bus:
(axis)
Power Off / Power On
• Check KSP
• Check KPP
26132 Collective brake Brake cable monitor- • Check brake voltage => fault
fault, KPP/KSP ing device has sig- in all axes
(axis) naled short-circuit,
• Check motor / brake (meas-
overloading or break
ure)
in connection. / short-

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Troubleshooting KR C4 extended

Error no. Error Cause Remedy


circuit / overcurrent / • Check brake cable / motor
no brake connected cable
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP

12.9 KPP and KSP warning messages

Description

The warning messages have corresponding acknowledgement messages.


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

Error no. Warning Cause Remedy


26102 Device state: OK - -
26103 Internal error, The device has detec- • Reinitialize the drive bus:
KPP/KSP (axis) ted an internal error. Power Off / Power On
• Check KPP (see LEDs)
26104 IxT overload er- Axis overloaded • During start-up => excessive
ror, KPP/KSP load in program
Mean continuous cur-
(axis) rent too high • Reinitialize the drive bus:
Power Power Off / Power On
• During operation
Excessive load
‒ 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, Power unit overcurrent • Check motor cable
KPP/KSP (axis) (ground fault)
• Check motor
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26106 Overcurrent, Fault that briefly re- • Check trace recording of ax-
KPP/KSP (axis) sults in an overcurrent is/current
that exceeds the max-
• Check motor
imum current of the
KPP (short-circuit,…) • Check motor cable
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP

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Troubleshooting
Error no. Warning Cause Remedy
• Check KPP
26107 Intermediate cir- Overvoltage in inter- • Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
high, KPP/KSP operation
• Check mains voltage
(axis)
• Check ballast switch
• Excessive load during brak-
ing => reduce
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26108 Intermediate cir- Undervoltage in inter- • Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
low, KPP/KSP operation
• Check mains voltage
(axis)
• Check intermediate circuit
cabling
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP charging circuit
26109 Logic supply volt- Overvoltage in 27 V • Check 27 V supply
age too high, supply
• Check power supply to 27 V
KPP/KSP (axis)
power supply unit
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26110 Logic supply volt- Undervoltage in 27 V • Check 27 V supply
age too low, supply
• Check power supply to 27 V
KPP/KSP (axis)
power supply unit
• Check battery
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26111 Device tempera- Overtemperature • Check cabinet fan
ture too high,
• Check ambient temperature
KPP/KSP (axis)
• Load in program too high,
check load
• Dirt in cooling circuit =>
clean
• Check PC fan
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
• Check KPP
26112 Heat sink tem- Overtemperature, heat • Check cabinet fan
perature too sink
• Check ambient temperature

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Troubleshooting KR C4 extended

Error no. Warning Cause Remedy


high, KPP/KSP • Load in program too high,
(axis) 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
• Check KSP
• Check KPP
26113 Motor phase fail- Failure of motor phase • Check motor cable
ure, KPP/KSP
• Check motor
(axis)
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP
26114 Communication Communication error • Reinitialize the drive bus:
error, KPP/KSP on the controller bus Power Off / Power On
(axis)
• Check EtherCat cabling
• Check EtherCat stack
• Check CCU
• Check KPP
• Check KSP
26115 Unknown status Software error, Ether- -
flag received, Cat master
KPP/KSP (axis)
26116 Unknown device - -
status, KPP/KSP
(axis)
26117 Hardware fault, The device has detec- • Reinitialize the drive bus:
KPP/KSP (axis) ted an internal hard- Power Off / Power On
ware fault.
• Check device (see LEDs)
• Exchange device
26118 Mains phase fail- Failure of mains • Check power lead
ure, KPP/KSP phase
• Check KPP cabling
(axis)
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26119 Power supply Failure, supply voltage • Check power lead
failure, KPP/KSP below 300V
• Check KPP cabling
(axis)
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26120 Overvoltage dur- - • Mains voltage too high
ing charging,
• Too few capacitors connec-
KPP/KSP (axis)
ted (too few modules)
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP

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Troubleshooting
Error no. Warning Cause Remedy
• Check KSP, improbable
26122 Fault in brake re- KPP has detected an • Check ballast resistor
sistor, KPP/KSP error in the ballast cir-
• Check cabling between KPP
(axis) cuit
and ballast resistor
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26123 Ballast circuit Braking energy per- • Reduce heavy loads that are
overload, manently too high braked too frequently
KPP/KSP (axis)
• Check ballast resistor
• Check cabling between KPP
and ballast resistor
• Reinitialize the drive bus:
Power Off / Power On
• Check KPP
26131 Intermediate cir- - • Check intermediate circuit
cuit charging cabling
failed, KPP/KSP
• Reinitialize the drive bus:
(axis)
Power Off / Power On
• Check KSP
• Check KPP
26133 Collective brake Brake cable monitor- • Check brake voltage => fault
fault, KPP/KSP ing device has sig- in all axes
(axis) naled short-circuit,
• Check motor / brake (meas-
overloading or break
ure)
in connection. / short-
circuit / overcurrent / • Check brake cable / motor
no brake connected cable
• Reinitialize the drive bus:
Power Off / Power On
• Check KSP

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Decommissioning, storage and disposal KR C4 extended

13 Decommissioning, storage and disposal

13.1 Decommissioning

Description

This section describes all the work required for decommissioning the robot
controller if the robot controller is to be removed from the system. After
decommissioning, it is prepared for storage or for transportation to a differ-
ent location.
Following its removal, the robot controller may only be transported with lift-
ing tackle and a fork lift truck or pallet truck.

Precondition

• The removal site must be accessible with a crane or with a fork lift
truck for transportation.
• The crane and fork lift truck have an adequate carrying capacity.
• There is no hazard posed by system components.

Procedure

1. Release and unplug all peripheral connections.


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

13.2 Storage

Precondition

If the robot controller is to be put into long-term storage, the following


points must be observed:
• The place of storage must be as dry and dust-free as possible.
• Avoid temperature fluctuations.
• Avoid wind and drafts.
• Avoid condensation.
• Observe and comply with the permissible temperature ranges for stor-
age.
• Select a storage location in which the packaging materials cannot be
damaged.
• Only store the robot controller indoors.

Procedure

1. Clean robot controller. No dirt may remain on or in the robot controller.


2. Inspect the robot controller, both internally and externally, for damage.
3. Remove batteries and store in accordance with the manufacturer’s 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.

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Decommissioning, storage and disposal


8. Cover the robot controller with plastic film and seal it against dust.
If necessary, add a desiccant beneath the sheeting.

13.3 Disposal

When the robot controller reaches the end of its useful life, it can be 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 or-
dinary 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.

Subassembly, com-
Material, designation Note
ponent
Steel Screws and washers, -
robot controller hous-
ing
PUR Cable sheaths -
ETFE Flexible tube -
Copper Electrical cables, -
wires
EPDM Seals and covers -
CuZn (gold-plated) Connectors, contacts Dispose of without
dismantling
Steel (ST 52-3) Allen screws, washers -
PE Cable straps -
Electrical components Bus modules, boards, Dispose of as electri-
sensors cal scrap without dis-
assembling

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KUKA Service KR C4 extended

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

Availability

KUKA Customer Support is available in many countries. Please do not


hesitate to contact us if you have any questions.

Argentina
Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

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KUKA Service
Australia
KUKA Robotics Australia Pty Ltd
45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
info@kuka-robotics.com.au
www.kuka-robotics.com.au

Belgium
KUKA Automatisering + Robots N.V.
Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be

Brazil
KUKA Roboter do Brasil Ltda.
Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
info@kuka-roboter.com.br
www.kuka-roboter.com.br

Chile
Robotec S.A. (Agency)
Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl

China
KUKA Robotics China Co., Ltd.
No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
info@kuka-robotics.cn
www.kuka-robotics.com

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KUKA Service KR C4 extended

Germany
KUKA Deutschland GmbH
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
Hotline.robotics.de@kuka.com
www.kuka.com

France
KUKA Automatisme + Robotique SAS
Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr

India
KUKA India Pvt. Ltd.
Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
info@kuka.in
www.kuka.in

Italy
KUKA Roboter Italia S.p.A.
Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

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KUKA Service
Japan
KUKA Japan K.K.
YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
info@kuka.co.jp

Canada
KUKA Robotics Canada Ltd.
6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
info@kukarobotics.com
www.kuka-robotics.com/canada

Korea
KUKA Robotics Korea Co. Ltd.
RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com

Malaysia
KUKA Robot Automation (M) Sdn Bhd
South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
info@kuka.com.my

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KUKA Service KR C4 extended

Mexico
KUKA de México S. de R.L. de C.V.
Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
www.kuka-robotics.com/mexico

Norway
KUKA Sveiseanlegg + Roboter
Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
info@kuka.no

Austria
KUKA CEE GmbH
Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 732 784 752 0
Fax +43 732 793 880
KUKAAustriaOffice@kuka.com
www.kuka.at

Poland
KUKA Roboter CEE GmbH Poland
Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de

Portugal
KUKA Robots IBÉRICA, S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
info.portugal@kukapt.com
www.kuka.com

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KUKA Service
Russia
KUKA Russia OOO
1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
support.robotics.ru@kuka.com

Sweden
KUKA Svetsanläggningar + Robotar AB
A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se

Switzerland
KUKA Roboter CEE GmbH
Linz, Zweigniederlassung Schweiz
Heinrich Wehrli-Strasse 27
5033 Buchs
Switzerland
Tel. +41 62 837 43 20
info@kuka-roboter.ch

Slovakia
KUKA Roboter CEE GmbH
organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
support.robotics.cz@kuka.com

Spain
KUKA Iberia, S.A.U.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
comercial@kukarob.es

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KUKA Service KR C4 extended

South Africa
Jendamark Automation LTD (Agency)
76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan
KUKA Automation Taiwan Co. Ltd.
1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
info@kuka.com.tw

Thailand
KUKA (Thailand) Co. Ltd.
No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
HelpdeskTH@kuka.com

Czech Republic
KUKA Roboter CEE GmbH
organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
support.robotics.cz@kuka.com

Hungary
KUKA HUNGÁRIA Kft.
Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

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KUKA Service
USA
KUKA Robotics Corporation
51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
info@kukarobotics.com
www.kukarobotics.com

UK
KUKA Robotics UK Ltd
Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
service@kuka-robotics.co.uk
www.kuka-robotics.co.uk

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KR C4 extended

Index Control unit..................................................... 27


Controller state............................................. 147
2006/42/EU:2006............................................ 60
Controller System Panel..........................13, 17
2014/30/EU:2014............................................ 60
Controller System Panel LED display......... 147
2014/68/EU:2014............................................ 60
Controller System Panel LED error display 149
95/16/EC......................................................... 60
Cooling circuit, configuration.......................... 25
Cooling circuits............................................... 24
Counterbalancing system............................... 58
A CSP............................................................ 9, 17
Accessories.....................................................35 CSP LED display..........................................147
Additional components................................... 25 CSP LED error display................................ 149
Altitude............................................................ 27 CSP overview................................................. 17
Ambient temperature...................................... 26
ANSI/RIA R.15.06-2012................................. 61
Applied norms and regulations...................... 60
Automatic mode..............................................57
D
Danger zone................................................... 37
Axis limitation, mechanical............................. 47
Data cables.....................................................20
Axis range.......................................................37
Data cables X21, connecting.........................99
Declaration of conformity............................... 36
Declaration of incorporation.....................35, 36
B Decommissioning................................... 59, 160
Basic data.......................................................26 defective fuses..............................................144
Batteries................................................... 13, 18 Dimensions of boreholes......................... 30, 31
Batteries, exchanging (cabinet door)...........131 Dimensions of robot controller.......................28
Battery discharge protection, reversing....... 101 Dimensions, smartPAD holder....................... 30
BR M.................................................................9 Disposal......................................... 59, 160, 161
Brake defect................................................... 49 Documentation, industrial robot....................... 8
Brake release device......................................47 Drive controller............................................... 13
Braking distance............................................. 37 Drive power supply.........................................13
Bus devices.................................................... 19 Dual NIC........................................................... 9

C E
Cabinet Control Unit................................ 13, 16 EA................................................................... 10
Cabinet Control Unit LED display................140 EC declaration of conformity......................... 36
Cabinet Control Unit, exchanging................125 EDS...................................................................9
Cabinet Control Unit, fusing.........................144 EH..................................................................... 9
Cabinet cooling...............................................24 Electromagnetic compatibility (EMC):............ 61
Cabinet Interface Board................................. 16 Electromagnetic compatibility, EMC...............62
Cabinet type................................................... 26 EMC.................................................................. 9
Cable inlet X51...............................................70 EMC Directive.......................................... 36, 60
Cable lengths........................................... 28, 65 EMD.................................................................. 9
CCU............................................................9, 16 EMERGENCY STOP....................................105
CCU functions................................................ 16 EMERGENCY STOP device............. 44, 45, 49
CCU LED display, overview.........................140 EMERGENCY STOP, external................ 45, 52
CE mark..........................................................36 EMERGENCY STOP, local............................ 52
Charge............................................................ 18 EN 60204-1:2006/A1:2009............................. 61
CIB..............................................................9, 16 EN 61000-6-2:2005........................................ 61
CIP Safety........................................................ 9 EN 61000-6-4:2007 + A1:2011...................... 61
CK..................................................................... 9 EN 614-1:2006+A1:2009................................61
Cleaning work.................................................58 EN ISO 10218-1:2011.................................... 61
Connecting cables.......................................... 35 EN ISO 12100:2010....................................... 61
Connecting cables, connecting...................... 98 EN ISO 13849-1:2015....................................61
Connection conditions.................................... 64 EN ISO 13849-2:2012....................................61
Connection manager.................................... 105 EN ISO 13850:2015....................................... 60
Connection panel............................................13 Enabling device........................................45, 49
Control PC................................................13, 15 Enabling device, external............................... 46
Control PC components, exchanging.......... 114 Enabling switch.............................................106
Control PC, exchanging............................... 114 Enabling switches.................................... 45, 80
Control PC, functions..................................... 15 Environmental conditions............................... 26

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Equipotential bonding.............................. 26, 64 KEB brake resistor, exchanging.................. 138


Error states, CSP......................................... 149 KEB configuration variants.............................20
EtherCAT connection on the CIB.................. 86 KEB devices................................................... 20
Ethernet/IP........................................................ 9 KEB inverter, exchanging.............................136
Exchanging devices.............. 89, 101, 102, 119 KEB mains filter, exchanging.......................137
Exhaustive discharge, battery........................ 27 Keyboard.......................................................105
External axes........................................... 35, 38 Keyboard key................................................105
External fan, exchange.................................111 KLI.....................................................................9
External power supply, X55........................... 71 KOI....................................................................9
KONI................................................................. 9
KPC...................................................................9
F KPP............................................................ 9, 14
Fan..................................................................13 KPP and KSP warning messages...............156
Fan, external, exchange............................... 111 KPP error messages.................................... 152
Fan, internal, exchange................................113 KPP, exchanging...........................................119
Faults.............................................................. 50 KRL................................................................... 9
Filter mats.......................................................24 KSB...................................................................9
Floor mounting................................................30 KSB configuration variants.............................20
Full-load current....................................... 26, 64 KSB devices................................................... 20
Function test................................................... 51 KSI.................................................................... 9
Fuse elements................................................ 13 KSP.......................................................... 10, 15
KSP error messages.................................... 152
KSP, exchanging.......................................... 122
KSS.................................................................10
G KUKA Customer Support............................. 162
General safety measures............................... 49
KUKA Power Pack...................................13, 14
Ground leakage current................................. 26
KUKA Power Pack, 3x20 A, checking........ 151
KUKA Service...............................................162
KUKA Servo Pack................................... 13, 15
H KUKA Servo Pack, checking....................... 150
Handling equipment................................. 92, 94 KUKA smartPAD..............................27, 37, 104
Hard drive, exchanging................................ 118 KUKA smartPAD cable...................................20
Hazardous substances................................... 58 KUKA smartPAD holder (optional).................23
HMI................................................................... 9 KUKA smartPAD holder, fastening................ 65
Humidity class................................................ 27 KUKA smartPAD, X19....................................74

I L
Identification plate.........................................106 Labeling.......................................................... 48
Industrial robot................................................35 LAN Dual NIC network card, exchanging... 117
Infeed.............................................................. 20 LAN Onboard LED display.......................... 149
Installation, KUKA System Software........... 139 LED group: KPP communication................. 152
Intended use............................................ 12, 35 LED group: KSP axis control.......................151
Interface, EtherCAT X65................................ 73 LED group: KSP communication................. 151
Interfaces, connection panel.......................... 20 LED group: KSP device status....................151
Interfaces, discrete......................................... 76 Liability............................................................ 35
Interfaces, motherboard D3445-K..................22 Lifting frame....................................................92
Internal fan, exchange..................................113 Linear unit.......................................................35
Introduction....................................................... 8 Load voltage US1, X56..................................70
Load voltage US2, X56..................................70
Low-voltage power supply....................... 13, 18
J Low-voltage power supply unit, exchanging132
Jog keys....................................................... 105 Low Voltage Directive.....................................36
Jog mode................................................. 46, 49 Lower connection panel...........................20, 67

K M
KCB...................................................................9 Machine data.................................................. 52
KCB devices................................................... 19 Machinery Directive..................................36, 60
KEB...................................................................9 Mains filter...................................................... 18

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KR C4 extended

Mains filter, exchanging................................134 PMB................................................................ 16


Mains frequency.......................................26, 64 Positioner........................................................ 35
Maintenance.................................. 57, 108, 148 Power cable....................................................20
Maintenance symbols...................................108 Power failure...................................................18
Manipulator........................................ 10, 35, 37 Power Management Board............................ 16
Manual mode..................................................56 Power supply connection X1 Harting connec-
Material designation..................................... 161 tor..................................................................100
Mechanical end stops.................................... 47 Power supply connection, technical data26, 64
Minimum clearances, robot controller............29 Power supply connection, X1, Harting connec-
Mode selector switch....................................104 tor....................................................................67
Modifying the system configuration....89, 101, Power supply with battery backup.................16
119 Power supply without battery backup............16
Monitoring, physical safeguards.....................43 Power switched off......................................... 18
Monitoring, velocity.........................................46 Pressure Equipment Directive................. 58, 60
Motherboard battery, exchange....................117 Pressure relief plug, exchanging................. 133
Motherboard D3445-K..............................22, 23 Preventive maintenance work........................ 58
Motherboard, exchanging............................. 117 Procurement of spare parts..........................111
Motor box, connection examples...................87 Product description.........................................13
Motor cables................................................... 20 Protection rating............................................. 26
Motor connector X20......................................69 Protective equipment......................................46
Motor connector X7.1.....................................70 Purpose...........................................................12
Motor interfaces..............................................68

Q
N QBS................................................................ 10
NA................................................................... 10

R
O Rated supply voltage............................... 26, 64
Operation...................................................... 104 RDC................................................................ 10
Operator safety..................................41, 43, 49 RDC box, connection examples.................... 87
Operator safety acknowledgement................ 89 RDC functions................................................ 17
Operators........................................................ 39 RDC LED display, overview.........................145
Options............................................................35 Reaction distance........................................... 37
Overload......................................................... 49 Recommissioning..................................... 51, 97
Overview of robot controller...........................13 Reference switch, X42................................... 75
Overview, lower interfaces............................. 66 Release device............................................... 47
Overview, side interfaces............................... 84 Repair..................................................... 57, 111
Overview, start-up...........................................97 Resolver cable, length difference............28, 65
Resolver Digital Converter............................. 17
Resolver Digital Converter, exchanging...... 128
P Resolver Digital Converter, LED display..... 145
Panic position................................................. 45 Robot controller........................................13, 35
PC fan, exchanging...................................... 115 Robot controller, cleaning.............................110
PE cables....................................................... 20 Robot controller, installing.............................. 97
PE equipotential bonding, connecting......... 100 RTS.................................................................10
PE, equipotential bonding.............................. 87
PELV............................................................... 10
Performance level...........................................89 S
Performance Level......................................... 41 Safe operational stop...............................37, 46
Peripheral cables............................................20 Safeguards, external...................................... 48
Peripheral contactor....................................... 55 SafeOperation via Ethernet safety interface. 81
Permissible tolerance of rated voltage....26, 64 Safety..............................................................35
Personnel........................................................38 Safety controller..............................................42
PFH values..................................................... 89 Safety functions........................................41, 49
PL....................................................................89 Safety functions, Ethernet safety interface....76
Planning.......................................................... 62 Safety functions, overview............................. 41
Plant integrator............................................... 38 Safety instructions............................................ 8
Plates and labels............................................31 Safety of machinery.................................60, 61
PLC................................................................. 10 Safety options.................................................38

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Safety options, interfaces...............................76 T


Safety STOP 0............................................... 37 T1 (operating mode).......................................38
Safety STOP 1............................................... 37 T2 (operating mode).......................................38
Safety STOP 2............................................... 37 Target group................................................... 12
Safety STOP 0............................................... 37 Teach pendant......................................... 13, 35
Safety STOP 1............................................... 37 Technical data.................................................26
Safety STOP 2............................................... 38 Technology cabinet.........................................31
Safety stop, external...................................... 46 Terms used....................................................... 9
Safety zone.............................................. 37, 40 Terms used, safety......................................... 36
Safety, general................................................35 Touch screen................................................ 104
SATA connections.......................................... 10 Trademarks..................................................... 11
Selecting the operating mode................. 41, 42 Training........................................................... 12
Service life...................................................... 37 Transportation.......................................... 50, 92
SG FC.............................................................10 Transportation, fork lift truck.......................... 93
Short circuit current rating............................. 26 Transportation, lifting tackle........................... 92
SIB.................................................................. 10 Transportation, pallet truck.............................96
Side connection panel............................. 21, 85 Troubleshooting............................................ 140
Simulation....................................................... 57 Turn-tilt table...................................................35
Single point of control.................................... 59
SION............................................................... 10
Sleep mode, CSP.........................................148
Slot assignment, motherboard D3445-K....... 23 U
smartPAD......................................... 38, 50, 104 US1................................................................. 10
smartPAD cable extensions.....................28, 65 US2...........................................................10, 55
smartPAD holder, fastening..........................100 USB.................................................................10
smartPAD, plugging in....................................99 USB connection............................................106
Software..........................................................35 Use, contrary to intended use....................... 35
Software limit switches............................ 46, 49 Use, improper................................................. 35
SOP................................................................ 10 User.......................................................... 37, 39
Sound level.....................................................26
Space Mouse................................................105
SPOC..............................................................59 V
SPRT.............................................................. 10 Velocity monitoring......................................... 46
SRM................................................................ 10 Vibration resistance........................................ 27
SSB.................................................................10
Start-up.....................................................51, 97
Start-up mode........................................ 54, 102 W
Start-up overview............................................97 Warnings........................................................... 8
Start backwards key.....................................105 Weight.............................................................26
Start key............................................... 105, 106 Workspace................................................37, 40
Status keys................................................... 105
STOP 0.................................................... 36, 38
STOP 1.................................................... 36, 38
STOP 2.................................................... 36, 38
X
X19, KUKA smartPAD....................................74
Stop category 0.............................................. 38
X20, motor connector.....................................69
Stop category 1.............................................. 38
X21 US2, RDC interface................................74
Stop category 2.............................................. 38
X42, reference switch.....................................75
Stop category 1, Drive Ramp Stop............... 38
X55, external power supply........................... 71
STOP key..................................................... 105
X56..................................................................70
Stop reactions.................................................40
X65..................................................................73
STOP 1 - DRS............................................... 38
X67, KLI interfaces.........................................72
Stopping distance.................................... 37, 40
X7.1, motor connector....................................70
Storage................................................... 59, 160
XS1EC, XS2EC, XS5EC
Support request............................................ 162
EtherCAT interfaces for Böllhoff peripheral
Swing range for cabinet door........................ 29
equipment.................................................. 85
Switch, external power supply....................... 71
XS1EP, XS2EP, XS5EP
Switching on the robot controller.................103
24 V DC supply for Böllhoff peripheral
System impedance...................................26, 64
equipment.................................................. 86
System integrator.............................. 36, 38, 39

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