BA KR C4 Extended Ready2 Rivet en
BA KR C4 Extended Ready2 Rivet en
BA KR C4 Extended Ready2 Rivet en
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
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
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
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
9 Operation.................................................................................................. 104
9.1 KUKA smartPAD teach pendant........................................................................... 104
9.1.1 Front view.............................................................................................................. 104
9.1.2 Rear view............................................................................................................... 106
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
Index 170
1 Introduction
Safety
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.
Notices
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
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)
Introduction
1.4 Trademarks
2 Purpose
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
Product description
3 Product description
• 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
Ethernet switch
Product description
EtherCat coupler
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
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
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
3.4 Control PC
PC components
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)
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
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
Description
The Controller System Panel (CSP) is a display element for the operating
state and has the following connections:
• USB1
• USB2
• KSI (optional)
Overview
Description
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.
Description
Product description
3.11 Bus devices
Overview
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
KCB devices
KSB devices
KEB devices
Note
Overview
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
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.
Overview
Product description
Slot assignment
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.
Overview
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!
Product description
Configuration
4 Technical data
Basic data
Environmental conditions
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
Control unit
Control PC
KUKA smartPAD
Weight 1.1 kg
Protection rating (without USB IP 54
stick and USB connection closed
with a plug)
Cable lengths
Technical data
1 Front view
2 Side view
3 Top view
The minimum clearances that must be maintained for the robot controller
are indicated in the diagram (>>> Fig. 4-2).
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.
The diagram (>>> Fig. 4-3) shows the swing range for the door.
The diagram (>>> Fig. 4-4) shows the dimensions and drilling locations
for mounting on the robot controller or safety fence.
The dimensions of the boreholes for floor mounting are indicated in the di-
agram (>>> Fig. 4-5).
Technical data
Fig. 4-5: Boreholes for floor mounting
The diagram (>>> Fig. 4-6) shows the dimensions of the boreholes on the
KR C4 extended for fastening the technology cabinet.
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.
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
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!
Technical data
Item Description
4
KR C4 main switch
The main switch is connected to the robot.
5
Item Description
8
Safety
5 Safety
5.1 General
5.1.1 Liability
• 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
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
fications.
Misuse
EC declaration of conformity
Declaration of incorporation
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.
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.
5.2 Personnel
The following persons or groups of persons are defined for the industrial
robot:
• User
• Personnel
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.:
Personnel
• System integrator
• Operators, subdivided into:
‒ Start-up, maintenance and service personnel
‒ Operating personnel
‒ Cleaning personnel
System integrator
The industrial robot is safely integrated into a complete system by the sys-
tem integrator.
The system integrator is responsible for the following tasks:
Operators
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.
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
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.
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
Operating modes
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
Safety
Operat-
ing Use Velocities
mode
• Jog mode: Not possible
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.
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.
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.
Safety
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.
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.
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:
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.
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.
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.
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.
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.
Safety
Further information is contained in the operating and programming in-
structions.
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.
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.
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.
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:
Safety
• The button for acknowledging the safety gate is located outside the
space limited by the safeguards.
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
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!
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
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
Safety
Robot controller
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.
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:
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.
Safety
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.
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.
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.
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.
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.
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.
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
Use
• 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
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
Setup work in T2
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
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.
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.
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
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.
Safety
To ensure safe use of our products, we recommend regularly request-
ing up-to-date safety data sheets for hazardous substances.
Overview
• Submit interpreter
• PLC
• OPC server
• Remote control tools
• Tools for configuration of bus systems with online functionality
• KUKA.RobotSensorInterface
Since only the system integrator knows the safe states of actuators in the
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
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:
Name/Edition Definition
Safety
EN ISO 13849-1:2015 Safety of machinery:
Safety-related parts of control systems - Part 1: General principles
of design
6 Planning
Overview
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.
Planning
6.2 Installation conditions
The minimum clearances that must be maintained for the robot controller
are indicated in the diagram (>>> Fig. 6-1).
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.
The diagram (>>> Fig. 6-2) shows the swing range for the door.
Planning
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.
Cable lengths
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.
Planning
Lower connection panel
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.
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.
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
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
Planning
• Harting connector, HAN E Modular
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.
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
Connec-
Axis Axis servo Connection
tor insert
A7 A KPP G1 X2/X32
Description
Overview
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
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).
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
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.
Description
The following couplers can be supplied with power via connector X55:
• Switch
Necessary equipment
Pin Description
5 +24 V external
6 0 V external
7 +24 V internal
8 0 V internal
- PE
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
Planning
• Recommended connecting cable: Ethernet-compatible, min. category
CAT 5E
• Maximum cable cross-section: AWG22
Pin Description
1 TD+
2 TD-
3 RD+
6 RD-
Description
Necessary equipment
• RJ45 connector
Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
6 TPFI_N
Description
Necessary equipment
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
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
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).
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
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.
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
Pin Description
1 TA24V A
4 TA24V B
2 E_REF_A_24V
5 E_REF_B_24V
6 Not assigned
3 GND
Description
Reserved bits
Input byte 0
Planning
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)
Input byte 1
Output byte 0
Planning
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:
Output byte 1
Description
Signals
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
Input byte 2
Input byte 3
Input byte 4
Input byte 5
Input byte 6
Input byte 7
Output byte 2
Planning
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
Output byte 4
Output byte 5
Output byte 6
Output byte 7
Planning
Side connection panel
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.
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
Pin Description
1 TD+
2 TD-
3 RD+
6 RD-
Description
Necessary equipment
• AIDA Power
Pin Description
1 Us
2 GND
3 Up
4 GND
PE Mass
Description
Planning
Fig. 6-21: EtherCAT connection X44
1 CIB
2 EtherCAT connection X44
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).
Description
Planning
3 Equipotential bonding from the robot controller to the drive system
4 Equipotential bonding connection on the drive system (robot kine-
matic system)
Description
Exchanging devices
The PFH values relate to the specific safety functions of the different con-
Planning
troller variants.
Safety function groups:
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.
7 Transportation
Precondition
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.
Transportation
Fig. 7-1: Transportation using lifting tackle
Precondition
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.
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.
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.
Transportation
Fig. 7-3: Transportation with fork slots
1 Fork slots
Insert the forks of the fork lift truck between the anti-toppling bracket and
the cross-strut of the roller set.
1 Anti-toppling bracket
2 Cross-strut of the roller set
Precondition
1 Anti-toppling bracket
Electrical system
Procedure
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.
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
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
Procedure
Procedure
Pin Description
2 +24 V PS1
3 GND
9 TPF0_P
10 TPFI_P
11 TPF0_N
12 TPFI_N
Description
Procedure
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.
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
Procedure
Procedure
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
Procedure
Pin Description
1 L1
2 L2
3 L3
PE PE
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
Description
Exchanging devices
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
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.
Precondition
Procedure
9 Operation
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
Item Description
1 Button for disconnecting the smartPAD
• With key
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.
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.
Overview
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.
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.
10 Maintenance
Description
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
Tighten screw/nut
Clean component
Exchange battery
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.
Maintenance
Fig. 10-1: Maintenance points
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.
Work regulations
Procedure
Repair
11 Repair
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.
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.
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.
Procedure
Repair
Fig. 11-3: 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.
Description
Procedure
Precondition
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.
Repair
Fig. 11-5: Fastening elements of the control PC
1 Knurled nut
2 Tilt the PC
3 Lift the PC
3b Rail
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.
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.
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)
Repair
Fig. 11-8: Installing 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.
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
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.
Procedure
Repair
Fig. 11-9: Exchanging the hard drive
1 SATA connector
2 Power supply connector
3 Knurled screws on the underside
Description
Exchanging devices
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.
KPP 3 connections
Repair
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.
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.
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.
Repair
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
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.
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.
Repair
Fig. 11-15: KSP fastening
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.
Connections
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)
Repair
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.
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.
1 Tabs
2 Fastening screw
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.
Repair
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
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.
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.
Repair
9. Close the lid of the RDC box and screw it firmly in place.
Precondition
Procedure
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.
3. Insert the new battery blocks and plug in the battery connection ca-
bles.
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.
Precondition
Repair
Procedure
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.
Description
Procedure
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.
Procedure
1. Disconnect the mains filter from main switch Q1 and power circuit-
breaker Q3
1 Q1 cable wires
2 Q3 cable wires
Repair
2. Unscrew the fastening nuts on the mains filter cable to Q1 and Q3 on
the inside of the cabinet.
1 Fastening bolt
4. Unscrew the side panel fastening screws and take off the side panel.
1 Fastening screws
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.
Repair
• Observe the ESD guidelines.
Procedure
Fig. 11-31
1 PE connection
2 Power cables
3 Brake resistor
4 Motor cables
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.
Procedure
1 PE connection
2 Plug-in connections
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.
Procedure
Repair
5. Mount the rear panel of the controller.
12 Troubleshooting
Overview
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
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)
Overview
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
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
Overview
Troubleshooting
12.4 Controller System Panel LED display
Overview
Fig. 12-4
Controller state
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)
Troubleshooting
12.4.1 Controller System Panel LED error display
Error states
Overview
Description
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
Overview
Troubleshooting
1 LED group: axis control 3 LED group: communication
status
2 LED group: KSP device sta-
tus
Device status
Axis control
Communication
The green communication LEDs indicate the status of the bus connection.
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.
Overview
Communication
The green communication LEDs indicate the status of the bus connection:
LED Description
On Connected, no data transfer
Flashing Connected, data transfer
Off No connection
Description
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
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-
Description
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
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
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
13.2 Storage
Precondition
Procedure
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.
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
14 KUKA Service
Introduction
Information
Availability
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
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
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
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
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
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
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
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
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
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
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