BA KR C4 TDA2 en
BA KR C4 TDA2 en
BA KR C4 TDA2 en
KR C4
Variant: TDA2
Operating Instructions
Issued: 14.12.2011
Version: BA KR C4 TDA2 V3 en
KR C4
© Copyright 2011
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Terms used ................................................................................................................ 7
2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9
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 ........................................................................................................ 59
6.1 Electromagnetic compatibility (EMC) ......................................................................... 60
6.2 Installation conditions ................................................................................................ 60
6.3 Connection conditions ............................................................................................... 62
6.4 Fastening the KUKA smartPAD holder (optional) ...................................................... 63
6.5 Power supply connection via X1 Harting connector .................................................. 64
6.6 Fast Measurement inputs, XG233 ............................................................................. 64
6.7 Interbus connection XF215, XF212A and XF212B .................................................... 66
6.8 PROFIBUS connection XF215, XF212A and XF212B .............................................. 67
7 Transportation ............................................................................................. 81
7.1 Transportation using lifting tackle .............................................................................. 81
7.2 Transportation by fork lift truck ................................................................................... 82
7.3 Transportation by pallet truck ..................................................................................... 82
7.4 Transportation with the set of rollers (optional) .......................................................... 83
9 Operation ...................................................................................................... 95
9.1 KUKA smartPAD teach pendant ................................................................................ 95
9.1.1 Front view ............................................................................................................. 95
9.1.2 Rear view .............................................................................................................. 96
10 Maintenance ................................................................................................. 97
10.1 Checking SIB relay outputs ........................................................................................ 98
10.2 Cleaning the robot controller ...................................................................................... 99
1 Introduction
Notes These hints serve to make your work easier or contain references to further
information.
Term Description
CCU Cabinet Control Unit
CIB Cabinet Interface Board
CSP Controller System Panel. Display element and
connection point for USB and network
Dual NIC card Dual network card
EDS Electronic Data Storage (memory card)
EMD Electronic Mastering Device
EMC Electromagnetic compatibility
KCB KUKA Controller Bus
Term Description
KCP The KCP (KUKA Control Panel) teach pendant
has all the operator control and display functions
required for operating and programming the
industrial robot.
The KCP variant for the KR C4 is called KUKA
smartPAD. The general term “KCP”, however, is
generally used in this documentation.
KLI KUKA Line Interface. Connection to higher-level
control infrastructure (PLC, archiving)
KOI KUKA Operator Panel Interface
KPC Control PC
KPP KUKA Power Pack (drive power supply with
drive controller)
KRL KUKA Robot Language
KSB KUKA System Bus. Internal KUKA bus for inter-
nal networking of the controllers with each other
KSI KUKA Service Interface
KSP KUKA Servo Pack (drive controller)
KSS KUKA System Software.
Manipulator The robot arm and the associated electrical
installations.
RDC Resolver digital converter.
SATA connections Data bus for exchanging data between the pro-
cessor and the hard drive
US1 Load voltage (24 V) not switched
US2 Load voltage (24 V) switched. Deactivates actu-
ators, for example, when the drives are deacti-
vated.
USB Universal Serial Bus. Bus system for connecting
additional devices to a computer.
2 Purpose
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of electrical and electronic systems
Advanced knowledge of the robot controller
Advanced knowledge of the Windows operating system
Use The robot controller is intended solely for operating the following components:
KUKA industrial robots
KUKA linear units
KUKA positioners
Impermissible Any use or application deviating from the intended use is deemed to be imper-
misuse missible misuse; examples of such misuse include:
Transportation of persons and animals
Use as a climbing aid
Operation outside the permissible operating parameters
Use in potentially explosive environments
3 Product description
Connection panel
Set of rollers (optional)
Description The KUKA Power Pack (KPP) is the drive power supply and generates a rec-
tified intermediate circuit voltage from an AC power supply. This intermediate
circuit voltage is used to supply the internal drive controllers and external
drives. There are 4 different device variants, all having the same size. There
are LEDs on the KPP which indicate the operating state.
KPP without axis amplifier (KPP 600-20)
KPP with amplifier for one axis (KPP 600-20-1x40)
Peak output current 1x40 A
KPP with amplifier for two axes (KPP 600-20-2x40)
Peak output current 2x40 A
KPP with amplifier for one axis (KPP 600-20-1x64)
Peak output current 64 A
Description The KUKA Servo Pack (KSP) is the drive controller for the manipulator axes.
There are 3 different device variants, all having the same size. There are LEDs
on the KSP which indicate the operating state.
KSP for 3 axes (KSP 600-3x40)
Peak output current 3x 40 A
KSP for 3 axes (KSP 600-3x64)
Peak output current 3x 64 A
KSP for 3 axes (KSP 600-3x20)
Peak output current 3x 20 A
3.5 Control PC
Processor
Memory modules
Hard drive
LAN Dual NIC network card
PC fan
Optional modules, e.g. field bus cards
Functions The control PC (KPC) is responsible for the following functions of the robot
controller:
User interface
Program creation, correction, archiving, and maintenance
Sequence control
Path planning
Control of the drive circuit
Monitoring
Safety equipment
Communication with external periphery (other controllers, host computers,
PCs, network)
Description The Cabinet Control Unit (CCU) is the central power distributor and communi-
cation interface for all components of the robot controller. The CCU consists
of the Cabinet Interface Board (CIB) and the Power Management Board
(PMB). All data are transferred via this internal communication interface to the
controller for further processing. If the mains voltage fails, the control compo-
nents continue to be powered by batteries until the position data are saved and
the controller has shut down. The charge and quality of the batteries are
checked by means of a load test.
Description The Safety Interface Board (SIB) is an integral part of the safe customer inter-
face. 2 different SIBs are used in the robot controller, the Standard SIB and
the Extended SIB, depending on the configuration of the customer interface.
Each of the 2 boards can be operated on its own or jointly with the other one.
The Standard SIB and the Extended SIB essentially incorporate sensing, con-
trol and switching functions. The output signals are provided as electrically iso-
lated outputs.
The Standard SIB contains the following safe inputs and outputs:
5 safe inputs
3 safe outputs
The Extended SIB contains the following safe inputs and outputs:
8 safe inputs
8 safe outputs
Description The Resolver Digital Converter (RDC) is used to detect the motor position da-
ta. 8 resolvers can be connected to the RDC. In addition, the motor tempera-
tures are measured and evaluated. For non-volatile data storage, the EDS is
located in the RDC box.
The RDC is mounted in an RDC box on the base frame of the manipulator.
Description The Controller System Panel (CSP) is a display element for the operating state
and has the following connections:
USB1
USB2
KLI from the Cu switch
Overview
Description The low-voltage power supply unit provides power to the components of the
robot controller.
A green LED indicates the operating state of the low-voltage power supply
unit.
3.11 Batteries
Description In the event of a power failure, or if the power is switched off, the batteries en-
able the robot controller to be shut down in a controlled manner. The batteries
are charged via the CCU and the charge is checked and indicated.
Description The mains filter (interference suppressor filter) suppresses interference volt-
ages on the power cable.
Overview
3.14 Interfaces
Overview The connection panel of the robot controller consists of connections for the fol-
lowing cables:
Power cable / infeed
Connection panel
All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor di-
odes. RC elements and VCR resistors are not suitable.
Connection panel
All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor di-
odes. RC elements and VCR resistors are not suitable.
Connection panel
All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor di-
odes. RC elements and VCR resistors are not suitable.
Connection panel
All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor di-
odes. RC elements and VCR resistors are not suitable.
Description The optional KUKA smartPAD holder can be used to hang up the smartPAD
and its connecting cable on the door of the robot controller or on the safety
fence.
Overview
Description The control cabinet is divided into two cooling circuits. The inner zone, con-
taining the control and power electronics, is cooled by a heat exchanger. In the
outer zone, the ballast resistor and the heat sinks of the KPP and KSP are
cooled directly by ambient air.
Configuration
Overview The mounting plate for customer components can be used for external cus-
tomer equipment depending on the installed hardware options on the top-hat
rail.
4 Technical data
Basic data Control cabinet type KR C4
Color RAL 7035
Number of axes max. 8
Weight 150 kg
Protection classification IP 54
Sound level according to DIN average: 67 dB (A)
45635-1
Installation with other cabinets Side-by-side, clearance 50 mm
(with/without cooling unit)
Load on cabinet roof with even dis- 1,500 N
tribution
The cables of the power supply unit must not be routed together with
power-carrying cables.
Cable lengths For cable designations, standard lengths and optional lengths, please refer to
the operating instructions or assembly instructions of the manipulator.
The cables of the power supply unit must not be routed together with
power-carrying cables.
SIB outputs
The power contacts must only be fed from a safely isolated PELV
power supply unit. (>>> 4.1 "External 24 V power supply" Page 27)
The module must be exchanged when the number of switching cycles is ex-
ceeded.
SIB inputs Switching level of the inputs The state for the inputs is not
defined for the voltage range 5 V ...
11 V (transition range). Either the
ON state or the OFF state is set.
OFF state for the voltage range
from -3 V to 5 V (OFF range).
ON state for the voltage range from
11 V to 30 V (ON range).
Load current with 24 V supply volt- > 10 mA
age
Load current with 18 V supply volt- > 6.5 mA
age
Max. load current < 15 mA
Cable length, terminal - sensor < 50 m, or < 100 m wire length (out-
going and incoming lines)
Cable cross-section, test output - > 0.5 mm2
input connection
Capacitive load for the test outputs < 200 nF
per channel
Resistive load for the test outputs < 33 Ω
per channel
1 Front view
2 Side view
3 Top view
The minimum clearances that must be maintained for the robot controller are
indicated in the diagram (>>> Fig. 4-2 ).
The diagram (>>> Fig. 4-3 ) shows the swing range for the door.
The diagram (>>> Fig. 4-4 ) shows the dimensions and drilling locations for
mounting on the robot controller or safety fence.
The dimensions of the boreholes for floor mounting are indicated in the dia-
gram (>>> Fig. 4-5 ).
The diagram (>>> Fig. 4-6 ) shows the dimensions of the boreholes on the
KR C4 for fastening the technology cabinet.
The diagram (>>> Fig. 4-7 ) shows the dimensions of the boreholes on the
adapter rails for fastening the technology cabinet.
Overview The following plates and labels are attached to the robot controller.
The plates may vary slightly from the examples illustrated above de-
pending on the specific cabinet type or as a result of updates.
5 Safety
5.1 General
5.1.1 Liability
Safety infor- Safety information cannot be held against KUKA Roboter GmbH. Even if all
mation safety instructions are followed, this is not a guarantee that the industrial robot
will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the autho-
rization of KUKA Roboter GmbH. Additional components (tools, software,
etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus-
trial robot. The user is liable for any damage these components may cause to
the industrial robot or to other material property.
In addition to the Safety chapter, this document contains further safety instruc-
tions. These must also be observed.
The industrial robot is intended exclusively for the use designated in the “Pur-
pose” chapter of the operating instructions or assembly instructions.
Using the industrial robot for any other or additional purpose is considered im-
permissible misuse. The manufacturer cannot be held liable for any damage
resulting from such use. The risk lies entirely with the user.
Operating the industrial robot and its options within the limits of its intended
use also involves observance of the operating and assembly instructions for
Misuse Any use or application deviating from the intended use is deemed to be imper-
missible misuse. This includes e.g.:
Transportation of persons and animals
Use as a climbing aid
Operation outside the permissible operating parameters
Use in potentially explosive environments
Operation without additional safeguards
Outdoor operation
Declaration of The system integrator must issue a declaration of conformity for the complete
conformity system in accordance with the Machinery Directive. The declaration of confor-
mity forms the basis for the CE mark for the system. The industrial robot must
be operated in accordance with the applicable national laws, regulations and
standards.
The robot controller is CE certified under the EMC Directive and the Low Volt-
age Directive.
Declaration of The industrial robot as partly completed machinery is supplied with a declara-
incorporation tion of incorporation in accordance with Annex II B of the EC Machinery Direc-
tive 2006/42/EC. The assembly instructions and a list of essential
requirements complied with in accordance with Annex I are integral parts of
this declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly com-
pleted machinery remains impermissible until the partly completed machinery
has been incorporated into machinery, or has been assembled with other parts
to form machinery, and this machinery complies with the terms of the EC Ma-
chinery Directive, and the EC declaration of conformity is present in accor-
dance with Annex II A.
The declaration of incorporation, together with its annexes, remains with the
system integrator as an integral part of the technical documentation of the
complete machinery.
STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204-
1:2006.
Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may move.
The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance
The stopping distance is part of the danger zone.
Workspace The manipulator is allowed to move within its workspace. The work-
space is derived from the individual axis ranges.
Operator The user of the industrial robot can be the management, employer or
(User) delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distances.
KCP The KCP (KUKA Control Panel) teach pendant has all the operator con-
trol and display functions required for operating and programming the
industrial robot.
The KCP variant for the KR C4 is called KUKA smartPAD. The general
term “KCP”, however, is generally used in this documentation.
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safe operational stop The safe operational stop is a standstill monitoring function. It does not
stop the robot motion, but monitors whether the robot axes are station-
ary. If these are moved during the safe operational stop, a safety stop
STOP 0 is triggered.
The safe operational stop can also be triggered externally.
When a safe operational stop is triggered, the robot controller sets an
output to the field bus. The output is set even if not all the axes were sta-
tionary at the time of triggering, thereby causing a safety stop STOP 0 to
be triggered.
Safety STOP 0 A stop that is triggered and executed by the safety controller. The safety
controller immediately switches off the drives and the power supply to
the brakes.
Note: This stop is called safety STOP 0 in this document.
Safety STOP 1 A stop that is triggered and monitored by the safety controller. The brak-
ing process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. As soon as the manip-
ulator is at a standstill, the safety controller switches off the drives and
the power supply to the brakes.
When a safety STOP 1 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 1 can also be triggered externally.
Note: This stop is called safety STOP 1 in this document.
Safety STOP 2 A stop that is triggered and monitored by the safety controller. The brak-
ing process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. The drives remain acti-
vated and the brakes released. As soon as the manipulator is at a stand-
still, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 2 can also be triggered externally.
Note: This stop is called safety STOP 2 in this document.
Term Description
Stop category 0 The drives are deactivated immediately and the brakes are applied. The
manipulator and any external axes (optional) perform path-oriented
braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-main-
taining braking. The drives are deactivated after 1 s and the brakes are
applied.
Note: This stop category is called STOP 1 in this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a path-
maintaining braking ramp.
Note: This stop category is called STOP 2 in this document.
System integrator System integrators are people who safely integrate the industrial robot
(plant integrator) into a complete system and commission it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Motion axis which is not part of the manipulator but which is controlled
using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.
5.2 Personnel
The following persons or groups of persons are defined for the industrial robot:
User
Personnel
All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.
User The user must observe the labor laws and regulations. This includes e.g.:
The user must comply with his monitoring obligations.
The user must carry out instructions at defined intervals.
Personnel Personnel must be instructed, before any work is commenced, in the type of
work involved and what exactly it entails as well as any hazards which may ex-
ist. Instruction must be carried out regularly. Instruction is also required after
particular incidents or technical modifications.
Personnel includes:
System integrator
Operators, subdivided into:
Start-up, maintenance and service personnel
Operating personnel
Cleaning personnel
System integrator The industrial robot is safely integrated into a complete system by the system
integrator.
System inte-
Tasks Operator Programmer
grator
Switch robot controller
x x x
on/off
Start program x x x
Select program x x x
Select operating mode x x x
Calibration
x x
(tool, base)
Master the manipulator x x
Configuration x x
Programming x x
Start-up x
Maintenance x
Repair x
Decommissioning x
Transportation x
Stop reactions of the industrial robot are triggered in response to operator ac-
tions or as a reaction to monitoring functions and error messages. The follow-
ing tables show the different stop reactions according to the operating mode
that has been set.
The safety controller is a unit inside the control PC. It links safety-relevant sig-
nals and safety-relevant monitoring functions.
Safety controller tasks:
Switching off the drives; applying the brakes
Monitoring the braking ramp
Standstill monitoring (after the stop)
Velocity monitoring in T1
Evaluation of safety-relevant signals
Setting of safety-oriented outputs
Operat-
Use Velocities
ing mode
Program verification:
Programmed velocity, maxi-
For test operation, pro- mum 250 mm/s
T1 gramming and teach-
ing Jog mode:
Jog velocity, maximum 250 mm/
s
Program verification:
T2 For test operation Programmed velocity
Jog mode: Not possible
For industrial robots Program mode:
AUT without higher-level Programmed velocity
controllers Jog mode: Not possible
For industrial robots Program mode:
AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC Jog mode: Not possible
The operator safety signal is used for interlocking physical safeguards, e.g.
safety gates. Automatic operation is not possible without this signal. In the
event of a loss of signal during automatic operation (e.g. safety gate is
opened), the manipulator stops with a safety stop 1.
Operator safety is not active in the test modes T1 (Manual Reduced Velocity)
and T2 (Manual High Velocity).
The EMERGENCY STOP device for the industrial robot is the EMERGENCY
STOP button on the KCP. The button must be pressed in the event of a haz-
ardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP button is pressed:
The manipulator and any external axes (optional) are stopped with a safe-
ty stop 1.
Before operation can be resumed, the EMERGENCY STOP button must be
turned to release it.
There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the KCP is disconnected.
(>>> 5.5.7 "External EMERGENCY STOP device" Page 43)
External EMERGENCY STOP devices are connected via the customer inter-
face. External EMERGENCY STOP devices are not included in the scope of
supply of the industrial robot.
The enabling devices of the industrial robot are the enabling switches on the
KCP.
There are 3 enabling switches installed on the KCP. The enabling switches
have 3 positions:
Not pressed
Center position
Panic position
In the test modes, the manipulator can only be moved if one of the enabling
switches is held in the central position.
Releasing the enabling switch triggers a safety stop 2.
Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
It is possible, for a short time, to hold 2 enabling switches in the center po-
sition simultaneously. This makes it possible to adjust grip from one en-
abling switch to another one. If 2 enabling switches are held
simultaneously in the center position for a longer period of time, this trig-
gers a safety stop after several seconds.
If an enabling switch malfunctions (jams), the industrial robot can be stopped
using the following methods:
Press the enabling switch down fully
Actuate the EMERGENCY STOP system
Release the Start key
External enabling devices are required if it is necessary for more than one per-
son to be in the danger zone of the industrial robot. They are connected to the
robot controller via interface X11 or PROFIsafe.
External enabling devices are not included in the scope of supply of the indus-
trial robot.
The safe operational stop can be triggered via an input on the customer inter-
face. The state is maintained as long as the external signal is FALSE. If the
external signal is TRUE, the manipulator can be moved again. No acknowl-
edgement is required.
Safety stop 1 and safety stop 2 can be triggered via an input on the customer
interface. The state is maintained as long as the external signal is FALSE. If
the external signal is TRUE, the manipulator can be moved again. No ac-
knowledgement is required.
The velocity at the TCP is monitored in T1 mode. If, due to an error, the veloc-
ity exceeds 250 mm/s, a safety stop 0 is triggered.
The axis ranges of all manipulator and positioner axes are limited by means of
adjustable software limit switches. These software limit switches only serve as
machine protection and must be adjusted in such a way that the manipulator/
positioner cannot hit the mechanical end stops.
The software limit switches are set during commissioning of an industrial ro-
bot.
The axis ranges of main axes A1 to A3 and wrist axis A5 of the manipulator
are limited by means of mechanical end stops with buffers.
Additional mechanical end stops can be installed on the external axes.
Some manipulators can be fitted with mechanical axis range limitation in axes
A1 to A3. The adjustable axis range limitation systems restrict the working
range to the required minimum. This increases personal safety and protection
of the system.
In the case of manipulators that are not designed to be fitted with mechanical
axis range limitation, the workspace must be laid out in such a way that there
is no danger to persons or material property, even in the absence of mechan-
ical axis range limitation.
If this is not possible, the workspace must be limited by means of photoelectric
barriers, photoelectric curtains or obstacles on the system side. There must be
no shearing or crushing hazards at the loading and transfer areas.
This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Roboter GmbH.
Some manipulators can be fitted with dual-channel axis range monitoring sys-
tems in main axes A1 to A3. The positioner axes may be fitted with additional
axis range monitoring systems. The safety zone for an axis can be adjusted
and monitored using an axis range monitoring system. This increases person-
al safety and protection of the system.
This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Roboter GmbH.
Description The release device can be used to move the manipulator manually after an ac-
cident or malfunction. The release device can be used for the main axis drive
motors and, depending on the robot variant, also for the wrist axis drive mo-
tors. It is only for use in exceptional circumstances and emergencies (e.g. for
freeing people).
Procedure 1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
2. Remove the protective cap from the motor.
3. Push the release device onto the corresponding motor and move the axis
in the desired direction.
The directions are indicated with arrows on the motors. It is necessary to
overcome the resistance of the mechanical motor brake and any other
loads acting on the axis.
All plates, labels, symbols and marks constitute safety-relevant parts of the in-
dustrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
Identification plates
Warning labels
Safety symbols
Designation labels
Cable markings
Rating plates
The access of persons to the danger zone of the industrial robot must be pre-
vented by means of safeguards. It is the responsibility of the system integrator
to ensure this.
Physical safeguards must meet the following requirements:
They meet the requirements of EN 953.
They prevent access of persons to the danger zone and cannot be easily
circumvented.
They are sufficiently fastened and can withstand all forces that are likely
to occur in the course of operation, whether from inside or outside the en-
closure.
They do not, themselves, represent a hazard or potential hazard.
The prescribed minimum clearance from the danger zone is maintained.
Safety gates (maintenance gates) must meet the following requirements:
They are reduced to an absolute minimum.
The interlocks (e.g. safety gate switches) are linked to the operator safety
input of the robot controller via safety gate switching devices or safety
PLC.
Switching devices, switches and the type of switching conform to the re-
quirements of Performance Level d and category 3 according to EN ISO
13849-1.
Depending on the risk situation: the safety gate is additionally safeguarded
by means of a locking mechanism that only allows the gate to be opened
if the manipulator is safely at a standstill.
The button for acknowledging the safety gate is located outside the space
limited by the safeguards.
Other safety Other safety equipment must be integrated into the system in accordance with
equipment the corresponding standards and regulations.
The following table indicates the operating modes in which the safety functions
are active.
The industrial robot may only be used in perfect technical condition in accor-
dance with its intended use and only by safety-conscious persons. Operator
errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial robot
even after the robot controller has been switched off and locked. Incorrect in-
stallation (e.g. overload) or mechanical defects (e.g. brake defect) can cause
the manipulator or external axes to sag. If work is to be carried out on a
switched-off industrial robot, the manipulator and external axes must first be
moved into a position in which they are unable to move on their own, whether
the payload is mounted or not. If this is not possible, the manipulator and ex-
ternal axes must be secured by appropriate means.
KCP The user must ensure that the industrial robot is only operated with the KCP
by authorized persons.
If more than one KCP is used in the overall system, it must be ensured that
each KCP is unambiguously assigned to the corresponding industrial robot.
They must not be interchanged.
External An external keyboard and/or external mouse may only be used if the following
keyboard, conditions are met:
external mouse Start-up or maintenance work is being carried out.
The drives are switched off.
There are no persons in the danger zone.
The KCP must not be used as long as an external keyboard and/or external
mouse are connected.
The external keyboard and/or external mouse must be removed as soon as
the start-up or maintenance work is completed or the KCP is connected.
Faults The following tasks must be carried out in the case of faults in the industrial
robot:
Switch off the robot controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
Indicate the fault by means of a label with a corresponding warning (tag-
out).
Keep a record of the faults.
Eliminate the fault and carry out a function test.
Modifications After modifications to the industrial robot, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety circuits
must also be tested.
New or modified programs must always be tested first in Manual Reduced Ve-
locity mode (T1).
After modifications to the industrial robot, existing programs must always be
tested first in Manual Reduced Velocity mode (T1). This applies to all compo-
nents of the industrial robot and includes modifications to the software and
configuration settings.
5.8.2 Transportation
Manipulator The prescribed transport position of the manipulator must be observed. Trans-
portation must be carried out in accordance with the operating instructions or
assembly instructions of the manipulator.
Robot controller The robot controller must be transported and installed in an upright position.
Avoid vibrations and impacts during transportation in order to prevent damage
to the robot controller.
Transportation must be carried out in accordance with the operating instruc-
tions or assembly instructions of the robot controller.
External axis The prescribed transport position of the external axis (e.g. KUKA linear unit,
(optional) turn-tilt table, etc.) must be observed. Transportation must be carried out in ac-
cordance with the operating instructions or assembly instructions of the exter-
nal axis.
Before starting up systems and devices for the first time, a check must be car-
ried out to ensure that the systems and devices are complete and operational,
that they can be operated safely and that any damage is detected.
The valid national or regional work safety regulations must be observed for this
check. The correct functioning of all safety circuits must also be tested.
The passwords for logging onto the KUKA System Software as “Ex-
pert” and “Administrator” must be changed before start-up and must
only be communicated to authorized personnel.
If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Roboter GmbH, are integrated into the industrial
robot, the user is responsible for ensuring that these components do
not adversely affect or disable safety functions.
Function test The following tests must be carried out before start-up and recommissioning:
General test:
It must be ensured that:
The industrial robot is correctly installed and fastened in accordance with
the specifications in the documentation.
There are no foreign bodies or loose parts on the industrial robot.
All required safety equipment is correctly installed and operational.
The power supply ratings of the industrial robot correspond to the local
supply voltage and mains type.
The ground conductor and the equipotential bonding cable are sufficiently
rated and correctly connected.
The connecting cables are correctly connected and the connectors are
locked.
Test of the safety functions:
A function test must be carried out for the following safety functions to ensure
that they are functioning correctly:
Local EMERGENCY STOP device (= EMERGENCY STOP button on the
KCP)
External EMERGENCY STOP device (input and output)
Enabling device (in the test modes)
Operator safety
All other safety-relevant inputs and outputs used
Other external safety functions
4. Calculate the velocity from the length of the path and the time measured
for execution of the motion.
Control of reduced velocity is functioning correctly if the following results are
achieved:
The calculated velocity does not exceed 250 mm/s.
The manipulator executes the path as programmed (i.e. in a straight line,
without deviations).
Machine data It must be ensured that the rating plate on the robot controller has the same
machine data as those entered in the declaration of incorporation. The ma-
chine data on the rating plate of the manipulator and the external axes (option-
al) must be entered during start-up.
Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 or CRR mode in the
absence of the safety periphery. (CRR is an operating mode specifically for
use with SafeOperation.)
If an SIB interface is used:
Start-up mode is always possible if all input signals have the state “logic
zero”. If this is not the case, the robot controller prevents or terminates
Start-up mode.
If the PROFIsafe interface is used:
If a connection to a higher-level safety system exists or is established, the
robot controller prevents or terminates Start-up mode.
Misuse Any use or application deviating from the designated use is deemed to be im-
permissible misuse. This includes, for example, use by any other personnel.
KUKA Roboter GmbH accepts no liability for damage or injury caused thereby.
The risk lies entirely with the user.
Manual mode is the mode for setup work. Setup work is all the tasks that have
to be carried out on the industrial robot to enable automatic operation. Setup
work includes:
Jog mode
Teach
Programming
Program verification
The following must be taken into consideration in manual mode:
If the drives are not required, they must be switched off to prevent the ma-
nipulator or the external axes (optional) from being moved unintentionally.
New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).
The manipulator, tooling or external axes (optional) must never touch or
project beyond the safety fence.
Workpieces, tooling and other objects must not become jammed as a re-
sult of the industrial robot motion, nor must they lead to short-circuits or be
liable to fall off.
All setup work must be carried out, where possible, from outside the safe-
guarded area.
If the setup work has to be carried out inside the safeguarded area, the follow-
ing must be taken into consideration:
In Manual Reduced Velocity mode (T1):
If it can be avoided, there must be no other persons inside the safeguard-
ed area.
If it is necessary for there to be several persons inside the safeguarded ar-
ea, the following must be observed:
Each person must have an enabling device.
All persons must have an unimpeded view of the industrial robot.
Eye-contact between all persons must be possible at all times.
The operator must be so positioned that he can see into the danger area
and get out of harm’s way.
In Manual High Velocity mode (T2):
This mode may only be used if the application requires a test at a velocity
higher than Manual Reduced Velocity.
Teaching and programming are not permissible in this operating mode.
Before commencing the test, the operator must ensure that the enabling
devices are operational.
The operator must be positioned outside the danger zone.
There must be no other persons inside the safeguarded area. It is the re-
sponsibility 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 regulations
must be observed for this check. The correct functioning of all safety circuits
must also be tested.
The purpose of maintenance and repair work is to ensure that the system is
kept operational or, in the event of a fault, to return the system to an operation-
al state. Repair work includes troubleshooting in addition to the actual repair
itself.
The following safety measures must be carried out when working on the indus-
trial robot:
Carry out work outside the danger zone. If work inside the danger zone is
necessary, the user must define additional safety measures to ensure the
safe protection of personnel.
Switch off the industrial robot and secure it (e.g. with a padlock) to prevent
it from being switched on again. If it is necessary to carry out work with the
robot controller switched on, the user must define additional safety mea-
sures to ensure the safe protection of personnel.
If it is necessary to carry out work with the robot controller switched on, this
may only be done in operating mode T1.
Label the system with a sign indicating that work is in progress. This sign
must remain in place, even during temporary interruptions to the work.
The EMERGENCY STOP systems must remain active. If safety functions
or safeguards are deactivated during maintenance or repair work, they
must be reactivated immediately after the work is completed.
Faulty components must be replaced using new components with the same
article numbers or equivalent components approved by KUKA Roboter GmbH
for this purpose.
Cleaning and preventive maintenance work is to be carried out in accordance
with the operating instructions.
Robot controller Even when the robot controller is switched off, parts connected to peripheral
devices may still carry voltage. The external power sources must therefore be
switched off if work is to be carried out on the robot controller.
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 components
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.
Counterbal- Some robot variants are equipped with a hydropneumatic, spring or gas cylin-
ancing system der counterbalancing system.
The hydropneumatic and gas cylinder counterbalancing systems are pressure
equipment and, as such, are subject to obligatory equipment monitoring. De-
pending on the robot variant, the counterbalancing systems correspond to cat-
egory 0, II or III, fluid group 2, of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and stan-
dards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order,
Sections 14 and 15. Inspection by the user before commissioning at the instal-
lation site.
The following safety measures must be carried out when working on the coun-
terbalancing system:
Hazardous The following safety measures must be carried out when handling hazardous
substances substances:
Avoid prolonged and repeated intensive contact with the skin.
Avoid breathing in oil spray or vapors.
Clean skin and apply skin cream.
Overview If certain components in the industrial robot are operated, safety measures
must be taken to ensure complete implementation of the principle of “single
point of control” (SPOC).
Components:
Submit interpreter
PLC
OPC Server
Remote control tools
Tools for configuration of bus systems with online functionality
KUKA.RobotSensorInterface
External keyboard/mouse
Since only the system integrator knows the safe states of actuators in the pe-
riphery of the robot controller, it is his task to set these actuators to a safe
state, e.g. in the event of an EMERGENCY STOP.
T1, T2 In the test modes, the components referred to above (with the exception of the
external keyboard/mouse) may only access the industrial robot if the following
signals have the following states:
Submit inter- If motions, (e.g. drives or grippers) are controlled with the Submit interpreter
preter, PLC or the PLC via the I/O system, and if they are not safeguarded by other means,
then this control will take effect even in T1 and T2 modes or while an EMER-
GENCY STOP is active.
If variables that affect the robot motion (e.g. override) are modified with the
Submit interpreter or the PLC, this takes effect even in T1 and T2 modes or
while an EMERGENCY STOP is active.
Safety measures:
In the test modes, the system variable $OV_PRO must not be written to
by the Submit interpreter or the PLC.
Do not modify safety-relevant signals and variables (e.g. operating mode,
EMERGENCY STOP, safety gate contact) via the Submit interpreter or
PLC.
If modifications are nonetheless required, all safety-relevant signals and
variables must be linked in such a way that they cannot be set to a dan-
gerous state by the Submit interpreter or PLC.
OPC server, These components can be used with write access to modify programs, outputs
remote control or other parameters of the robot controller, without this being noticed by any
tools persons located inside the system.
Safety measures:
KUKA stipulates that these components are to be used exclusively for di-
agnosis and visualization.
Programs, outputs or other parameters of the robot controller must not be
modified using these components.
If these components are used, outputs that could cause a hazard must be
determined in a risk assessment. These outputs must be designed in such
a way that they cannot be set without being enabled. This can be done us-
ing an external enabling device, for example.
Tools for configu- If these components have an online functionality, they can be used with write
ration of bus access to modify programs, outputs or other parameters of the robot control-
systems ler, without this being noticed by any persons located inside the system.
WorkVisual from KUKA
Tools from other manufacturers
Safety measures:
In the test modes, programs, outputs or other parameters of the robot con-
troller must not be modified using these components.
External These components can be used to modify programs, outputs or other param-
keyboard/mouse eters of the robot controller, without this being noticed by any persons located
inside the system.
Safety measures:
Only use one operator console at each robot controller.
If the KCP is being used for work inside the system, remove any keyboard
and mouse from the robot controller beforehand.
6 Planning
Overview Step Description Information
1 Electromagnetic compatibility (>>> 6.1 "Electro-
(EMC) magnetic compatibility
(EMC)" Page 60)
2 Installation conditions for robot (>>> 6.2 "Installation
controller conditions" Page 60)
3 Connection conditions (>>> 6.3 "Connection
conditions" Page 62)
4 Mounting the KUKA smartPAD (>>> 4.6 "Dimensions of
holder (optional) the smartPAD holder
(optional)" Page 30)
5 Power supply connection (>>> 6.5 "Power supply
connection via X1 Hart-
ing connector" Page 64)
6 “Fast Measurement” connection (>>> 6.6 "Fast Measure-
ment inputs, XG233"
Page 64)
7 Interbus connection (>>> 6.7 "Interbus con-
nection XF215, XF212A
and XF212B" Page 66)
8 PROFIBUS connection (>>> 6.8 "PROFIBUS
connection XF215,
XF212A and XF212B"
Page 67)
9 RoboTeam connection (>>> 6.9 "RoboTeam
connection XF270 and
XF271" Page 68)
10 Ethernet connection (>>> 6.10 "Ethernet con-
nection XF217 and
XF218" Page 68)
11 Configure interface XD211 (>>> 6.11 "Description
of interface XD211"
Page 68)
(>>> 6.11.1 "Connector
pin allocation XD211"
Page 70)
12 Operator Safety acknowledge- (>>> 6.12 "Operator
ment safety acknowledge-
ment" Page 77)
13 PE equipotential bonding (>>> 6.13 "PE equipo-
tential bonding" Page 77)
14 Load voltage US1 and US2 (>>> 6.14 "Load voltage
US1 and US2" Page 78)
15 Modification of the system struc- (>>> 11.4 "Modifying the
ture, exchange of devices system configuration,
exchanging devices"
Page 109)
16 Performance Level (>>> 6.16 "Performance
level" Page 79)
Description If connecting cables (e.g. field buses, etc.) are routed to the control PC from
outside, only shielded cables with an adequate degree of shielding may be
used. The cable shield must be connected with maximum surface area to the
PE rail in the cabinet using shield terminals (screw-type, no clamps).
1 Front view
2 Side view
3 Top view
The minimum clearances that must be maintained for the robot controller are
indicated in the diagram (>>> Fig. 6-2 ).
The diagram (>>> Fig. 6-3 ) shows the swing range for the door.
Robot controller One robot controller can be stacked one on top of another one. The upper ro-
stacked bot controller must be screwed securely to the lower one using the 4 tapped
holes of the eyebolts. The lower robot controller must not be mounted on roll-
ers and must be fastened to the floor.
Cable lengths For cable designations, standard lengths and optional lengths, please refer to
the operating instructions or assembly instructions of the manipulator.
The cables of the power supply unit must not be routed together with
power-carrying cables.
Overview The smartPAD holder can be installed on the door of the robot controller or on
the safety fence.
The following diagram (>>> Fig. 6-5 ) shows the options for fastening the
smartPAD holder.
Description A Harting connector bypack is supplied with the robot controller. The customer
can connect the robot controller to the power supply via connector X1.
Connector pin
allocation
Connector
contact diagram
Connector pin
allocation
Connector pin
allocation
Connector pin
allocation
Connector pin
allocation
Description EMERGENCY STOP devices must be connected via the interface XD211 or
linked together by means of higher-level controllers (e.g. PLC). (>>> "SIB
outputs" Page 27)
Wiring Take the following points into consideration when wiring interface XD211:
System concept
Safety concept
Connector pin
allocation
Signal “Peri The signal “Peri enabled” is set to 1 (active) if the following conditions are met:
enabled” Drives are activated.
Safety controller motion enable signal present.
The message “Operator safety open” must not be active.
“Peri enabled” in conjunction with the signal “Safe operational stop”
In the case of activation of the signal “Safe operational stop” during the
motion:
Error -> braking with Stop 0. “Peri enabled” eliminated.
Activation of the signal “Safe operational stop” with the manipulator sta-
tionary:
Release the brakes, switch drives to servo-control and monitor for restart.
“Peri enabled” remains active.
Signal “FF motion enable” remains active.
US2 voltage (if present) remains active.
Signal “Peri enabled” remains active.
“Peri enabled” in conjunction with the signal “Safety stop 2”
In the case of activation of the signal “Safety stop 2”:
Stop 2 of the manipulator.
Signal “Drive enable” remains active.
Brakes remain released.
Manipulator remains under servo-control.
Monitoring for restart active.
Signal “Motion enable” is deactivated.
US2 voltage (if present) is deactivated.
Signal “Peri enabled” is deactivated.
In the cabling for the input signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the voltages (e.g. separate cabling of input signals and test signals).
In the cabling for the output signals and test signals in the system,
suitable measures must be taken to prevent a cross-connection be-
tween the output signals of a channel (e.g. separate cabling).
External enabling
switch
Fig. 6-14: Interface XD211, connector pin allocation for external enabling
switch
Internal/external
power supply
Test outputs A and B are fed with the supply voltage of the SIB. Test outputs
A and B are sustained short-circuit proof. The test outputs must only be used
to supply the SIB inputs, and for no other purpose.
The wiring example can be used to achieve compliance with SIL2 (DIN EN
62061), Cat. 3 (DIN EN 13849).
Dynamic testing The switch-off capability of the inputs is tested cyclically. For this, the test
outputs TA_A and TA_B are switched off alternately.
The switch-off pulse length is defined for the SIBs as t1 = 625 μs (125 μs
– 2.375 ms).
The duration t2 between two switch-off pulses on one channel is 106 ms.
The input channel SIN_x_A must be supplied by the test signal TA_A. The
input channel SIN_x_B must be supplied by the test signal TA_B. No other
power supply is permissible.
It is only permitted to connect sensors which allow the connection of test
signals and which provide floating contacts.
The signals TA_A and TA_B must not be significantly delayed by the
switching element.
Switch-off pulse
diagram
Safe output On the SIB, the outputs are provided as dual-channel floating relay outputs.
The following diagram illustrates the connection of a safe output to a safe input
provided by the customer with external test facility. The input used by the cus-
tomer must be monitored externally for cross-connection.
1 SIB
2 Robot controller
3 Interface X11 (XD211) or X13 (XD213)
4 Output wiring
5 System side
6 Safe input (Fail Safe PLC, safety switching device)
7 Test output channel B
8 Test output channel A
9 Input X, channel A
10 Input X, channel B
The wiring example shown can be used to achieve compliance with SIL2 (DIN
EN 62061), Cat. 3 (DIN EN 13849).
Description In the case of interfaces with switchable load voltage US1/US2, load voltage
US1 is not switched and US2 is wired using failsafe technology so that actua-
tors, for example, are switched off when the drives are deactivated.
The second main contactor can be used as a switching element for the unin-
terruptible power supply (US2) to the peripheral devices. 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 telegram). This variant is available only if PROFIsafe 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 between
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.
Procedure PROFIsafe:
Set US2 input; contactor switches on.
Reset US2 input; contactor switches off.
Automatic:
Press enabling switch; contactor switches on; manipulator can be moved.
Release enabling switch; contactor switches off.
Deactivated:
In this configuration, it is not necessary to check the US2 contactor. The
outputs must not be used.
External PLC In this configuration, the US2 contactor can be checked by deactivating the in-
put “Peripheral contactor (US2)” in the PROFIsafe telegram.
KRC In this configuration, the US2 contactor can be checked by opening the oper-
ator safety device (safeguard) in “Automatic” or “Automatic External” mode
and releasing the enabling switch in “T1” or “T2” mode.
Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
Installation of KSS/VSS 8.2
This is the case if a KSS/VSS 8.2 package is installed without KSS/VSS
8.2 already being present (because it has been uninstalled or deleted or
has never been installed).
The hard drive has been exchanged.
A device has been replaced by a device of a different type.
More than one device has been replaced by a device of a different type.
One or more devices have been removed.
One or more devices have been added.
Two or more devices have been interchanged.
Exchanging If a device is exchanged, at least one KCB, KSB or KEB device is replaced by
devices a device of the same type. Any number of KCB, KSB and KEB devices can be
exchanged until all devices in the KCB, KSB and KEB have been replaced si-
multaneously by devices of the same type. Simultaneous exchange of two
identical components of the KCB is not possible. Only one of the identical com-
ponents may be exchanged at any one time.
The safety functions of the robot controller conform to category 3 and Perfor-
mance Level d according to EN ISO 13849-1.
For controller variants that are not listed here, please contact KUKA
Roboter GmbH.
7 Transportation
Procedure 1. Attach the lifting tackle with or without a lifting frame to all 4 transport eye-
bolts on the robot controller.
Procedure
Procedure
Description The robot controller rollers may only be used to roll the cabinet into and out of
a row of cabinets – not to transport the cabinet over longer distances. The floor
must be level and free from obstacles, as there is a permanent risk of toppling.
This overview refers to the start-up of the industrial robot. The start-
up of the overall system is not within the scope of this documentation.
Manipulator
Electrical system
Procedure 1. Install the robot controller. The minimum clearances to walls, other cabi-
nets, etc. must be observed. (>>> 4.3 "Dimensions of robot controller"
Page 28) (>>> 6.2 "Installation conditions" Page 60)
2. Check the robot controller for any damage caused during transportation.
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 fastened.
6. The operator must cover the warning label Read manual with the label in
the relevant local language. (>>> 4.9 "Plates and labels" Page 32)
Overview A connecting cable set is supplied with the industrial robot. In the standard
version this consists of:
Motor cables to the manipulator
Data cables to the manipulator
The following cables may be provided for additional applications:
Motor cables for external axes
Peripheral cables
Procedure 1. Route the motor cables to the manipulator junction box separately from the
data cables. Connect standard connector X20 (or X20.1/X20.4 for heavy-
duty robot).
2. Route the motor cables of external axes 7 and 8 (optional) to the manipu-
lator junction box separately from the data cables. Insert connectors X7.1
and X7.2.
3. Route the data cables to the manipulator junction box separately from the
motor cable. Plug in connector X21.
4. Connect the peripheral cables.
Connector pin
allocation
Connector pin
allocation
Connector pin
allocation
Connector pin
allocation
Connector pin
allocation
Procedure Fasten the smartPAD holder on the door of the robot controller or on the
wall. (>>> 6.4 "Fastening the KUKA smartPAD holder (optional)"
Page 63)
Connector pin
allocation X19
Description The robot controller is connected to the mains via a Harting connector X1.
Procedure Connect the robot controller to the power supply via X1.
Description To prevent the batteries from discharging before the controller has been start-
ed up for the first time, the robot controller is supplied with connector X305 dis-
connected from the CCU.
Procedure 1. Configure connector XD211 in accordance with the system and safety
concepts. (>>> 6.11 "Description of interface XD211" Page 68)
2. Connect interface connector XD211 to the robot controller.
Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
Installation of KSS/VSS 8.2
This is the case if a KSS/VSS 8.2 package is installed without KSS/VSS
8.2 already being present (because it has been uninstalled or deleted or
has never been installed).
The hard drive has been exchanged.
A device has been replaced by a device of a different type.
More than one device has been replaced by a device of a different type.
One or more devices have been removed.
One or more devices have been added.
Two or more devices have been interchanged.
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 pro-
gramming the industrial robot.
The smartPAD has a touch screen: the smartHMI can be operated with a fin-
ger or stylus. An external mouse or external keyboard is not necessary.
The general term “KCP” (KUKA Control Panel) is often used in this documen-
tation for the smartPAD.
Overview
Overview
10 Maintenance
Description Maintenance work must be performed at the specified maintenance intervals
after commissioning by the customer.
Maintenance
symbols
Oil change
Tighten screw/nut
Clean component
Exchange battery
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
Once an activity from the maintenance list has been carried out, a visual in-
spection must be made, with special attention to the following points:
Check that fuses, contactors, plug-in connections and boards are fitted se-
curely.
Damage to cabling.
Check PE equipotential bonding connection.
Wear and damage to any system components.
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The controller has been shut down.
The power cable is de-energized.
Work regulations The manufacturer’s instructions must be observed when using cleaning
agents for cleaning work.
It must be ensured that no cleaning agents enter electrical components.
Do not use compressed air during cleaning work.
Do not spray with water.
11 Repair
Repair Repairs to the robot controller may only be carried out by KUKA customer sup-
port personnel or by customers who have taken part in a relevant course of
training held by KUKA Roboter GmbH.
Repairs within modules may only be carried out by specially trained KUKA Ro-
boter GmbH personnel.
Procurement of The article numbers of the spare parts are listed in the spare parts catalog.
spare parts KUKA Roboter GmbH supplies the following types of spare parts for repairs to
the robot controller:
New parts
Once the new part has been installed, the part that has been removed can
be disposed of.
Exchange parts
Once the exchange part has been installed, the part that has been re-
moved is returned to KUKA Roboter GmbH.
A “Robot Repair Card” is supplied with the exchange parts. The Re-
pair Card must be completed and returned to KUKA Roboter GmbH.
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
11.3 Control PC
Overview
Interfaces
Slot assignment
Processor
Memory modules
Interfaces to all PC components
On-board network card
KUKA Roboter GmbH has assembled, tested and supplied the moth-
erboard with an optimum configuration. No liability will be accepted
for modifications to the configuration that have not been carried out
by KUKA Roboter GmbH.
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
Procedure 1. Unplug the power supply and all connections to the control PC.
2. Slacken the knurled nuts.
3. Remove the control PC and lift it out towards the top.
4. Insert the new control PC and fasten.
5. Plug in the connections.
1 Knurled nut
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
Procedure 1. Remove the control PC. (>>> 11.3.1 "Exchanging the control PC"
Page 105)
2. Remove the cover of the control PC.
3. Release and unplug the fan connector.
7. Fasten the 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. 11-10 ).
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
Once the hard drive has been exchanged, the archive of the previous
installation can be loaded (as an alternative to configuration using
WorkVisual).
1 SATA connection
2 Power supply connection
3 Knurled screws on the underside
Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
Installation of KSS/VSS 8.2
This is the case if a KSS/VSS 8.2 package is installed without KSS/VSS
8.2 already being present (because it has been uninstalled or deleted or
has never been installed).
The hard drive has been exchanged.
A device has been replaced by a device of a different type.
More than one device has been replaced by a device of a different type.
One or more devices have been removed.
One or more devices have been added.
Two or more devices have been interchanged.
Exchanging If a device is exchanged, at least one KCB, KSB or KEB device is replaced by
devices a device of the same type. Any number of KCB, KSB and KEB devices can be
exchanged until all devices in the KCB, KSB and KEB have been replaced si-
multaneously by devices of the same type. Simultaneous exchange of two
identical components of the KCB is not possible. Only one of the identical com-
ponents may be exchanged at any one time.
Connections
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
Procedure 1. Unlock connectors X20 and X21 of the data cables. Unplug all connections
to the KPP.
3. Lift the KPP slightly, tilt the top forwards and lift the KPP out of the support
bracket.
4. Insert the new KPP into the support bracket, hook it on at the top and tight-
en the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable la-
beling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
configuration of the industrial robot must be configured using WorkVisual.
Connections
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
Procedure 1. Unlock connectors X20 and X21 of the data cables. Unplug all connections
to the KSP.
3. Lift the KSP slightly, tilt the top forwards and lift the KPP out of the support
bracket.
4. Insert the new KSP into the support bracket, hook it on at the top and tight-
en the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable la-
beling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
configuration of the industrial robot must be configured using WorkVisual.
Connections
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable is de-energized.
Procedure 1. Unlock the data cable connectors. Unplug all connections to the CCU.
2. Remove the screw on the fastening plate and pull the plate with the CCU
out of the tab slots.
3. Check the new CCU for mechanical damage. Insert the fastening plate
with the CCU into the tab slots and screw it firmly in place.
4. Plug in all the connections in accordance with the connector and cable la-
beling. Lock the data cable connectors.
1 Tabs
2 Fastening screw
Standard connec-
tions
Extended
connections
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable is de-energized.
Procedure 1. Unlock the data cable connectors. Unplug all connections to the SIB.
2. Remove the screw on the fastening plate and pull the plate with the SIB
out of the tab slots.
3. Check the new SIB for mechanical damage. Insert the fastening plate with
the SIB into the tab slots and screw it firmly in place.
4. Plug in all the connections in accordance with the connector and cable la-
beling. Lock the data cable connectors.
5. If exchanging the SIB resulted in a system modification, the system con-
figuration of the industrial robot must be configured using WorkVisual.
1 Fastening screw
2 Tabs
Connections
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
Procedure 1. Remove the screws from the lid of the RDC box.
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.
9. Close the lid of the RDC box and screw it firmly in place.
Procedure 1. Shut down the robot controller by means of the main menu item Shut-
down. [Further information is contained in the operating and programming
instructions for the KUKA System Software.]
2. Turn off the robot controller and take measures to prevent it from being
turned on again unintentionally.
3. Disconnect the power cable from the supply.
8. Insert the new battery blocks and plug in the battery connection cables.
Storage
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable is de-energized.
Description The pressure relief plug is used to generate an overpressure inside the cabi-
net. This prevents excessive fouling of the cabinet.
Preconditions The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
The power cable must be de-energized.
12 Troubleshooting
Overview
Overview
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
Overview
Overview
Fig. 12-4
Overview
Fig. 12-5
Error states
Overview
Standard
Extended
Semiconductor Every output channel is fitted with self-resetting semiconductor fuses to guard
fuse against short-circuits.
To reset the semiconductor fuse, the following steps are to be carried out:
Eliminate the cause of the error
De-energize the semiconductor fuse for 5 s
The semiconductor fuses are not rated for frequent use and should
not be tripped intentionally, as this will reduce their service life.
Standard SIB
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
Extended SIB
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
Description The KSP LED display consists of the following LED groups:
KSP device status
Axis control
Drive bus status
If faults occur during the initialization phase, the middle axis control LEDs
flash. All other LEDs are off. The red axis control LED is lit continuously and
the green axis control LED flashes at 2 to 16 Hz, followed by a pause.
If defective firmware is detected during the initialization phase, the red device
status LED is lit and the green device status LED is dimmed.
Precondition
The robot controller is energized (50-600 V) when it is
switched on. This voltage can cause life-threatening inju-
ries on contact. Work and measurements on the electrical equipment may
only be carried out by specially trained personnel.
Overview
Description The KPP LED display consists of the following LED groups:
Supply
KPP device status
Axis control
Drive bus status
If faults occur during the initialization phase, the middle axis control LEDs
flash. All other LEDs are off. The red axis control LED is lit continuously and
the green axis control LED flashes at 2 to 16 Hz, followed by a pause.
If defective firmware is detected during the initialization phase, the red device
status LED is lit and the green device status LED is dimmed.
Precondition
The robot controller is energized (50-600 V) when it is
switched on. This voltage can cause life-threatening inju-
ries on contact. Work and measurements on the electrical equipment may
only be carried out by specially trained personnel.
Overview
13.1 Decommissioning
Description This section describes all the work required for decommissioning the robot
controller if the robot controller is to be removed from the system. After decom-
missioning, it is prepared for storage or for transportation to a different loca-
tion.
Following its removal, the robot controller may only be transported with lifting
tackle and a fork lift truck or pallet truck.
Precondition The removal site must be accessible with a crane or with a fork lift truck for
transportation.
The crane and fork lift truck have an adequate carrying capacity.
There is no hazard posed by system components.
13.2 Storage
Preconditions If the robot controller is to be put into long-term storage, the following points
must be observed:
The place of storage must be as dry and dust-free as possible.
Avoid temperature fluctuations.
Avoid wind and drafts.
Avoid condensation.
Observe and comply with the permissible temperature ranges for storage.
Select a storage location in which the packaging materials cannot be dam-
aged.
Only store the robot controller indoors.
Procedure 1. Clean robot controller. No dirt may remain on or in the robot controller.
2. Inspect the robot controller, both internally and externally, for damage.
3. Remove batteries and store in accordance with the manufacturer’s instruc-
tions.
4. Remove any foreign bodies.
5. Remove any corrosion expertly.
6. Attach all covers to the robot controller and check that the seals are cor-
rectly in place.
7. Seal off electrical connections with suitable covers.
8. Cover the robot controller with plastic film and seal it against dust.
If necessary, add a desiccant beneath the sheeting.
13.3 Disposal
When the robot controller reaches the end of its useful life, it can be disman-
tled, and the materials can be disposed of properly by type.
The following table provides an overview of the materials used in the robot
controller. Some of the plastic components are marked with a material desig-
nation and must be disposed of accordingly.
14 KUKA Service
Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Index
Numbers Controller System Panel LED display 133
2004/108/EC 57 Controller System Panel LED error display 134
2006/42/EC 57 Cooling circuits 22
89/336/EEC 57 Counterbalancing system 54
95/16/EC 57 CSP 7, 16
97/23/EC 57 CSP LED display 133
CSP LED error display 134
A CSP overview 16
Accessories 11, 35 Customer equipment 23
Applied norms and regulations 57
Automatic mode 53 D
Axis range 37 Danger zone 37
Axis range limitation 45 Data cables 18, 91
Axis range monitoring 46 Declaration of conformity 36
Declaration of incorporation 35, 36
B Decommissioning 55, 153
Batteries 11, 17 Defective fuse 131, 140
Batteries, exchanging 122 Dimensions of boreholes 30, 31
Battery discharge protection, reversing 93 Dimensions of robot controller 28
Brake defect 48 Dimensions, smartPAD holder 30
Braking distance 37 Disposal 55, 153
Bus devices 17 Documentation, industrial robot 7
Drive controller 11
C Drive power supply 11
Cabinet Control Unit 11, 14 Dual NIC card 7
Cabinet Control Unit LED display 127 Dual NIC network card, exchanging 108
Cabinet Control Unit, exchange 115 Dynamic testing 75
Cabinet Control Unit, fusing 131
Cabinet cooling 22 E
Cabinet Interface Board 14 EC declaration of conformity 36
Cable lengths 27, 63 EDS 7
CCU 7, 14 Electromagnetic compatibility, EMC 60
CCU functions 14 EMC 7
CCU LED display, overview 127 EMC Directive 36, 57
CE mark 36 EMD 7
Charge 17 EMERGENCY STOP button 43, 50
CIB 7, 14 EMERGENCY STOP device 43, 48
Cleaning work 54 EMERGENCY STOP, external 43, 50
Configuration of cooling circuit 22 EMERGENCY STOP, local 50
Connecting cables 11, 35 EN 60204-1 57
Connecting cables, standard 86 EN 61000-6-2 57
Connection conditions 62 EN 61000-6-4 57
Connection panel 12 EN 614-1 57
Connector pin allocation X20 88 EN ISO 10218-1 57
Connector pin allocation XF212A 66, 67 EN ISO 12100-1 57
Connector pin allocation XF212B 66, 67 EN ISO 12100-2 57
Connector pin allocation XF215 66, 67 EN ISO 13849-1 57
Connector pin allocation XF218 68 EN ISO 13849-2 57
Connector pin allocation XF227 68 EN ISO 13850 57
Connector pin allocation XF270 68 Enabling device 44, 48
Connector pin allocation XF271 68 Enabling device, external 44
Connector pin allocation, XG233 65 Enabling switch 96
Control PC 11, 13, 103 Enabling switches 44
Control PC, exchanging 105 Environmental conditions 26
Control PC, functions 14 Error states, CSP 135
Control PC, overview 103 Exchanging devices 79, 109
Control unit 26 Extended SIB, connections 118
Controller System Panel 11, 16 Extended SIB, fuse 140
Extended SIB, LED display 138 KUKA Servo Pack, exchange 112
External axes 35, 38 KUKA smartPAD 26, 37, 95
External enabling switch 73 KUKA smartPAD cable 18
External enabling switch function 73 KUKA smartPAD holder (optional) 21
External fan, exchange 101 KUKA smartPAD holder, fastening 63
External voltage 25, 27, 63
L
F Labeling 47
Fans 11 LAN Onboard LED display 135
Faults 49 LED group KPP axis control 143
Filter mats 22 LED group KPP device status 143
Floor mounting 30 LED group KPP drive bus 143
Function test 50 LED group KPP power supply 143
Fuse elements 11 LED group KSP axis control 142
LED group KSP device status 141
G LED group KSP drive bus 142
General safety measures 48 Liability 35
Guard interlock 42 Lifting frame 81
Linear unit 35
H Load voltage US1 78
Hard drive, exchanging 108 Load voltage US2 78
Hazardous substances 55 Low Voltage Directive 36
Low-voltage power supply unit 11, 16
I Low-voltage power supply unit, exchanging 124
Identification plate 96
Industrial robot 11, 35 M
Infeed 17 Machine data 51
Inputs, Fast Measurement 64 Machinery Directive 36, 57
Installation, KUKA System Software 126 Mains filter 17
Intended use 9, 35 Maintenance 53, 97
Interbus interface for heavy-duty robots 21 Maintenance symbols 97
Interface XD211, description 68 Manipulator 8, 11, 35, 37, 40
Interfaces 17 Manual mode 52
Introduction 7 Material designation 154
Mechanical axis range limitation 45
J Mechanical end stops 45
Jog mode 45, 48 Memory modules 105
Minimum clearances, robot controller 29
K Mode selection 41, 42
KCB 7 Modifying the system configuration 79, 109
KCP 8, 37, 48, 95 Monitoring, velocity 45
Keyboard, external 49 Motherboard 104
KLI 8 Motherboard battery, exchange 108
KOI 8 Motherboard, exchange 109
KPC 8 Motor cable, external axis 7 90
KPP 8, 13 Motor cable, external axis 8 90
KPP and KSP warning messages 147 Motor cables 18
KPP error messages 144 Motor cables, heavy-duty robot 89
KRL 8 Motor cables, X20 88
KSB 8 Mounting plate for customer components 23
KSI 8 Mouse, external 49
KSP 8, 13
KSP error messages 144 O
KSS 8 On-board network card 105
KUKA Control Panel 95 Operation 95
KUKA Customer Support 155 Operator 37, 39
KUKA Power Pack 11, 13 Operator safety 41, 42, 48
KUKA Power Pack, checking 142 Operator safety acknowledgement 77
KUKA Power Pack, exchange 110 Options 11, 35
KUKA Servo Pack 11, 13 Overload 48
KUKA Servo Pack, checking 141 Overview of the industrial robot 11
Overview, start-up 85 S
Safe operational stop 37, 44
P Safeguards, external 47
Panic position 44 Safely isolated 25, 27, 63
PC fan, exchanging 106 Safety 35
PC interfaces 105 Safety controller 41
PE cables 18 Safety functions 48
PE equipotential bonding 77 Safety functions, overview 41
PE equipotential bonding, connecting 92 Safety instructions 7
PELV power supply unit 25, 27, 63 Safety Interface Board 11, 15, 27
Performance level 79 Safety Interface Board, exchanging 118
Performance Level 41 Safety Interface Board, fuses 139
Peripheral cables 18 Safety Interface Board, LED display 136
Personnel 38 Safety STOP 0 37
PFH values 80 Safety STOP 1 37
PL 79 Safety STOP 2 37
Plant integrator 38 Safety STOP 0 37
Plates and labels 32 Safety STOP 1 37
PMB 14 Safety STOP 2 37
Positioner 35 Safety stop, external 44, 45
Power cable 17 Safety zone 37, 39, 40
Power cable, connecting 92 Safety, general 35
Power failure 17 SATA connections 8
Power Management Board 14 Selective 25, 62
Power supply connection X1 Harting connector Semiconductor fuse 139
64 Service, KUKA Roboter 155
Power supply connection, technical data 25, 62 SIB 15, 27
Power supply with battery backup 15 SIB description 15
Power supply without battery backup 15 SIB functions 15
Power supply, internal/external 74 SIB inputs 28
Power switched off 17 SIB LED display, overview 136
Pressure Equipment Directive 54, 57 SIB outputs 27
Pressure relief plug, exchanging 125 SIB relay outputs, checking 98
Preventive maintenance work 54 SIB wiring 69
Processor 105 SIB, safe input 74
Procurement of spare parts 101 SIB, safe output 76
Product description 11 Signal “Peri enabled” 72
PROFIBUS interface for heavy-duty robots 20 Simulation 53
Protective equipment 45 Single point of control 55
Purpose 9 Sleep mode, CSP 134
smartPAD 37, 95
R smartPAD holder, fastening 91
RCCB, trip current difference 25, 62 smartPAD, plugging in 91
RDC 8 Software 11, 35
RDC functions 15 Software limit switches 45, 48
RDC LED display, overview 132 SPOC 55
Reaction distance 37 Standard Interbus interface 18
Recommissioning 50, 85 Standard PROFIBUS interface 19
Release device 46 Standard SIB, connections 118
Repair 53, 101 Standard SIB, fuses 140
Resolver Digital Converter 15 Start key 96
Resolver Digital Converter, exchange 120 Start-up 50, 85
Resolver Digital Converter, LED display 132 Start-up mode 51
Robot controller 11, 35 Start-up overview 85
Robot controller stacked 61 STOP 0 36, 38
Robot controller, cleaning 99 STOP 1 36, 38
Robot controller, installing 86 STOP 2 36, 38
Robot controller, overview 11 Stop category 0 38
RoboTeam connection 68 Stop category 1 38
Stop category 2 38
Stop reactions 40
T
T1 38
T2 38
Target group 9
Teach pendant 11, 35
Technical data 25
Technology cabinet 31
Terms used 7
Terms used, safety 36
Test output A 71, 73
Test output B 71
Touch screen 95
Training 9
Transport position 49
Transportation 49, 81
Transportation, fork lift truck 82
Transportation, lifting tackle 81
Transportation, pallet truck 82
Transportation, set of rollers 83
Troubleshooting 127
Turn-tilt table 35
U
Universal-current sensitive 25, 62
US1 8
US2 8
US2 function, checking 79
USB 8
USB connection 96
Use, contrary to intended use 35
Use, improper 35
User 37, 38
V
Velocity monitoring 45
Vibration resistance 26
W
Warnings 7
Working range limitation 45
Workspace 37, 39, 40
X
X19 connector pin allocation 92
X20.1 connector pin allocation 89
X20.4 connector pin allocation 89
X21 connector pin allocation 91
X7.1 connector pin allocation 90
X7.2 connector pin allocation 90
XD211, configuring 93