Page 1 KUKA Roboter GmbH Controller KR C4 Operating Instructions Issued: 12.08.2011 Version: BA KR C4 GI V4 en...
Page 2 Subject to technical alterations without an effect on the function. Translation of the original documentation KIM-PS5-DOC Publication: Pub BA KR C4 GI en Bookstructure: BA KR C4 GI V4.9 Label: BA KR C4 GI V4 en Issued: 12.08.2011 Version: BA KR C4 GI V4 en 2 / 179...
Page 3: Table Of Contents
Dimensions of boreholes for floor mounting .............. Dimensions of boreholes for technology cabinet ............Plates and labels ......................Safety ......................General ........................5.1.1 Liability ........................5.1.2 Intended use of the industrial robot ..............Issued: 12.08.2011 Version: BA KR C4 GI V4 en 3 / 179...
Page 4 Connection conditions ....................Fastening the KUKA smartPAD holder (optional) ............Power supply connection via X1 Harting connector ..........Description of interface X11 ..................6.6.1 Connector pin allocation X11 ................Issued: 12.08.2011 Version: BA KR C4 GI V4 en 4 / 179...
Page 5 KUKA smartPAD teach pendant ................9.1.1 Front view ......................9.1.2 Rear view ......................Maintenance ....................10.1 Checking SIB relay outputs ..................10.2 Checking Extended SIB relay outputs ............... Issued: 12.08.2011 Version: BA KR C4 GI V4 en 5 / 179...
Page 6 Decommissioning, storage and disposal ..........13.1 Decommissioning ...................... 13.2 Storage ........................13.3 Disposal ........................KUKA Service ....................14.1 Requesting support ....................14.2 KUKA Customer Support ................... Index ......................Issued: 12.08.2011 Version: BA KR C4 GI V4 en 6 / 179...
Page 7: Introduction
Tip to make your work easier or reference to further information. Trademarks Windows is a trademark of Microsoft Corporation. is a trademark of Beckhoff Automation GmbH. Terms used Term Description Cabinet Control Unit Cabinet Interface Board Issued: 12.08.2011 Version: BA KR C4 GI V4 en 7 / 179...
Page 8 The KCP variant for the KR C4 is called KUKA smartPAD. The general term “KCP”, however, is generally used in this documentation. KUKA Extension Bus KUKA Line Interface.
Page 9: Purpose
 For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at www.kuka.com or can be ob- tained directly from our subsidiaries.
Page 10 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 10 / 179...
Page 11: Product Description
The robot controller consists of the following components: Control PC (KPC)  Low-voltage power supply unit  Drive power supply with drive controller: KUKA Power Pack (KPP)  Drive controller: KUKA Servo Pack (KSP)  Teach pendant (KUKA smartPAD) ...
Page 12 Drive controller for axes 1 to 3 KUKA smartPAD Brake filter Fig. 3-3: Overview of robot controller, rear view Ballast resistor External fan Heat exchanger Low-voltage power supply unit Issued: 12.08.2011 Version: BA KR C4 GI V4 en 12 / 179...
Page 13: Kuka Power Pack
3 Product description KUKA Power Pack The KUKA Power Pack (KPP) is the drive power supply and generates a rec- Description tified intermediate circuit voltage from an AC power supply. This intermediate circuit voltage is used to supply the internal drive controllers and external drives.
Page 14: Cabinet Control Unit
Alarm contact for main switch  Temperature sensor for ballast resistor  Temperature sensor for internal cabinet temperature  The following components are connected to the KPC via the KUKA Con-  troller Bus: KPP/KSP  Resolver digital converter ...
Page 15: Safety Interface Board
Detection of up to 8 motor operating temperatures  Communication with the robot controller  Monitoring of the resolver cables  The following non-volatile data are stored on the EDS:  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 15 / 179...
Page 16: Controller System Panel
External 24 V power supply is possible via the following interfaces: RoboTeam X57  If power is supplied externally and the controller is switched off, the SIB is in the fail-safe state. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 16 / 179...
Page 17: Batteries
KSP, left Standard/Extended SIB KSP, middle KUKA Extension Bus (KEB) Dual NIC card Ethernet motherboard Electronic Mastering Device (EMD) KUKA System Bus (KSB) KUKA Controller Bus (KCB) KUKA smartPAD Issued: 12.08.2011 Version: BA KR C4 GI V4 en 17 / 179...
Page 18: Kcb Devices And Configuration Variants
KEB devices PROFIBUS master  PROFIBUS slave  PROFIBUS master/slave  Expansion of digital I/Os 16/16  Digital I/Os 16/16  Digital I/Os 16/16/4  Digital I/Os 32/32/4  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 18 / 179...
Page 19: Interfaces
Only one of the two interfaces can be used at a time. The connection panel of the robot controller consists of connections for the fol- Overview lowing cables: Issued: 12.08.2011 Version: BA KR C4 GI V4 en 19 / 179...
Page 20 Assignment of slot 2 X20 Motor connector, axes 1-6  X20.4 Motor connector, heavy-duty robot, axes 4-6  X20.4 Motor connector, heavy-duty palletizing robot, axes 5 and 6  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 20 / 179...
Page 21: Kuka Smartpad Holder (Optional)
RC elements and VCR resistors are not suitable. 3.16 KUKA smartPAD holder (optional) The optional KUKA smartPAD holder can be used to hang up the smartPAD Description and its connecting cable on the door of the robot controller or on the safety fence.
Page 22: Description Of The Mounting Plate For Customer Components
The mounting plate for customer components can be used for external cus- Overview tomer equipment depending on the installed hardware options on the top-hat rail. Fig. 3-9: Mounting plate for customer components Mounting plate for customer components Issued: 12.08.2011 Version: BA KR C4 GI V4 en 22 / 179...
Page 23 3 Product description Technical data Designation Values Power dissipation of installed components max. 20 W Depth of installed components approx. 200 mm Width 300 mm Height 150 mm Issued: 12.08.2011 Version: BA KR C4 GI V4 en 23 / 179...
Page 24 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 24 / 179...
Page 25: Technical Data
-25 ... +40 °C (248 to 313 K) Ambient temperature during storage/transportation with batteries -25 ... +70 °C (248 to 343 K) Ambient temperature during storage/transportation without batteries max. 1.1 K/min Temperature change Issued: 12.08.2011 Version: BA KR C4 GI V4 en 25 / 179...
Page 26 Display size Interfaces 1.1 kg Weight For cable designations, standard lengths and optional lengths, please refer to Cable lengths the operating instructions or assembly instructions of the manipulator. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 26 / 179...
Page 27: Ext. 24 V External Power Supply
Service life: 20 years Switching cycles, Extended SIB < 780,000 (corresponds to 106 switching cycles per day) The module must be exchanged when the number of switching cycles is ex- ceeded. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 27 / 179...
Page 28: Dimensions Of Robot Controller
This must be rated for the maximum current of 15 mA. Dimensions of robot controller The dimensions of the robot controller are indicated in the diagram (>>> Fig. 4-1 ). Issued: 12.08.2011 Version: BA KR C4 GI V4 en 28 / 179...
Page 29: Minimum Clearances, Robot Controller
Fig. 4-2: Minimum clearances If the minimum clearances are not maintained, this can result in damage to the robot controller. The specified minimum clearances must always be observed. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 29 / 179...
Page 30: Swing Range For Cabinet Door
(>>> Fig. 4-4 ) shows the dimensions and drilling locations for mounting on the robot controller or safety fence. Fig. 4-4: Dimensions and drilling locations for smartPAD holder Issued: 12.08.2011 Version: BA KR C4 GI V4 en 30 / 179...
Page 31: Dimensions Of Boreholes For Floor Mounting
Fig. 4-6: Fastening the technology cabinet View from above The diagram (>>> Fig. 4-7 ) shows the dimensions of the boreholes on the adapter rails for fastening the technology cabinet. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 31 / 179...
Page 32: Plates And Labels
KR C4 Fig. 4-7: Technology cabinet, fastening on mounting rails Plates and labels The following plates and labels are attached to the robot controller. Overview Issued: 12.08.2011 Version: BA KR C4 GI V4 en 32 / 179...
Page 33 Fig. 4-8: Plates and labels The plates may vary slightly from the examples illustrated above de- pending on the specific cabinet type or as a result of updates. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 33 / 179...
Page 34 Designation Robot controller identification plate Hot surface warning sign Hand injury warning sign Warning: read manual Control PC identification plate Warning: ≤ 780 VDC / wait 180 s Issued: 12.08.2011 Version: BA KR C4 GI V4 en 34 / 179...
Page 35: Safety
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.
Page 36: Ec Declaration Of Conformity And Declaration Of Incorporation
5.1.4 Terms used STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204- 1:2006. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 36 / 179...
Page 37 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...
Page 38: Personnel
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. Personnel The following persons or groups of persons are defined for the industrial robot: User ...
Page 39: Workspace, Safety Zone And Danger Zone
The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 39 / 179...
Page 40: Triggers For Stop Reactions
Safety stop 2 during operation Safety gate opened (oper- Safety stop 1 ator safety) Enabling switch released Safety stop 2 Enabling switch pressed Safety stop 1 fully down or error Issued: 12.08.2011 Version: BA KR C4 GI V4 en 40 / 179...
Page 41: Safety Functions
5.5.2 Safety controller The safety controller is a unit inside the control PC. It links safety-relevant sig- nals and safety-relevant monitoring functions. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 41 / 179...
Page 42: Mode Selection
(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). Issued: 12.08.2011 Version: BA KR C4 GI V4 en 42 / 179...
Page 43: Emergency Stop Device
If an SIB interface is used, this triggers an EMERGENCY STOP for the  overall system. If the PROFIsafe interface is used, the KUKA safety controller generates  a signal that prevents the higher-level controller from triggering an EMER- GENCY STOP for the overall system.
Page 44: External Emergency Stop Device
The enabling switches must not be held down by adhe- sive tape or other means or manipulated in any other way. Death, serious physical injuries or major damage to property may result. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 44 / 179...
Page 45: External Enabling Device
The software limit switches are set during commissioning of an industrial ro- bot. Further information is contained in the operating and programming in- structions. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 45 / 179...
Page 46: Mechanical End Stops
If the manipulator or an external axis hits an obstruction or a buffer on the mechanical end stop or axis range lim- itation, this can result in material damage to the industrial robot. KUKA Ro- boter GmbH must be consulted before the industrial robot is put back into operation.
Page 47: Labeling On The Industrial Robot
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.  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 47 / 179...
Page 48: Overview Of Operating Modes And Safety Functions
If this is not possible, the manipulator and ex- ternal axes must be secured by appropriate means. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 48 / 179...
Page 49 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). Issued: 12.08.2011 Version: BA KR C4 GI V4 en 49 / 179...
Page 50: Transportation
Transportation must be carried out in accordance with the operating instruc- tions or assembly instructions of the robot controller. The prescribed transport position of the external axis (e.g. KUKA linear unit, External axis turn-tilt table, etc.) must be observed. Transportation must be carried out in ac-...
Page 51 Death, severe physical injuries or considerable damage to property may otherwise result. The correct machine data must be loaded. Following modifications to the machine data, the safety configuration must be checked. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 51 / 179...
Page 52: Start-Up Mode
Misuse 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. Issued: 12.08.2011 Version: BA KR C4 GI V4 en...
Page 53: Manual Mode
Simulation programs do not correspond exactly to reality. Robot programs cre- ated in simulation programs must be tested in the system in Manual Reduced Velocity mode (T1). It may be necessary to modify the program. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 53 / 179...
Page 54: Automatic Mode
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.
Page 55: Decommissioning, Storage And Disposal
If certain components in the industrial robot are operated, safety measures Overview must be taken to ensure complete implementation of the principle of “single point of control” (SPOC). Components: Submit interpreter   OPC Server  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 55 / 179...
Page 56 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.
Page 57: Applied Norms And Regulations
Basic concepts, general principles for design - Part 2: Technical principles Industrial robots: 2008 EN ISO 10218-1 Safety Safety of machinery: 2006 EN 614-1 Ergonomic design principles - Part 1: Terms and general principles Issued: 12.08.2011 Version: BA KR C4 GI V4 en 57 / 179...
Page 58 2007 EN 61000-6-4 Part 6-4: Generic standards; Emission standard for indus- trial environments Safety of machinery: 2006 EN 60204-1 Electrical equipment of machines - Part 1: General requirements Issued: 12.08.2011 Version: BA KR C4 GI V4 en 58 / 179...
Page 59: Planning
EN 55011 and is intended for use in an industrial setting. Ascertaining the electromagnetic compatibility in other environments can result in difficulties due to conducted and radiated disturbance that may occur. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 59 / 179...
Page 60: Installation Conditions
Fig. 6-2: Minimum clearances If the minimum clearances are not maintained, this can result in damage to the robot controller. The specified minimum clearances must always be observed. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 60 / 179...
Page 61 The lower robot controller must not be mounted on roll- ers and must be fastened to the floor. A stacked robot controller is illustrated in the diagram (>>> Fig. 6-4 ). Issued: 12.08.2011 Version: BA KR C4 GI V4 en 61 / 179...
Page 62: Connection Conditions
The robot controller may only be operated with the supply volt- age specified on the rating plate. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 62 / 179...
Page 63: Fastening The Kuka Smartpad Holder (Optional)
The smartPAD holder can be installed on the door of the robot controller or on Overview the safety fence. The following diagram (>>> Fig. 6-5 ) shows the options for fastening the smartPAD holder. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 63 / 179...
Page 64: Power Supply Connection Via X1 Harting Connector
(e.g. PLC). (>>> "SIB outputs" Page 27) Take the following points into consideration when wiring interface X11: Wiring System concept  Safety concept  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 64 / 179...
Page 65: Connector Pin Allocation X11
6 Planning 6.6.1 Connector pin allocation X11 Connector pin allocation Fig. 6-7: Interface X11, connector pin allocation Issued: 12.08.2011 Version: BA KR C4 GI V4 en 65 / 179...
Page 66 55 / 56 EMERGENCY STOP on  channel B smartPAD not actuated Controller switched on and  operational The contacts open if any con- dition is not met. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 66 / 179...
Page 67 The signal “Peri enabled” is set to 1 (active) if the following conditions are met: Signal “Peri enabled” Drives are activated.  Safety controller motion enable signal present.  The message “Operator safety open” must not be active.  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 67 / 179...
Page 68: Wiring Example For Safe Inputs And Outputs
The following diagram illustrates the connection of a safe input to a floating contact provided by the customer. Fig. 6-9: Connection schematic for safe input Safe input, SIB Robot controller Issued: 12.08.2011 Version: BA KR C4 GI V4 en 68 / 179...
Page 69 Test output channel B SIN_X_A Input X, channel A SIN_X_B Input X, channel B On the SIB, the outputs are provided as dual-channel floating relay outputs. Safe output Issued: 12.08.2011 Version: BA KR C4 GI V4 en 69 / 179...
Page 70: Safety Functions Via Profisafe
0, then the manipulator would either not move or would unex- pectedly come to a standstill. KUKA recommends pre-assignment of the reserved inputs with 1. If a reserved input has a new safety function assigned to it, and the in- put is not used by the customer’s PLC, the safety function is not acti-...
Page 71 1.5 s. Cancelation of this function does not require acknowledgement. This function is not permissible for the EMERGENCY STOP function. 0 = safety stop is active 1 = safety stop is not active Issued: 12.08.2011 Version: BA KR C4 GI V4 en 71 / 179...
Page 72 0 = E2 keyswitch is not active 1 = E2 keyswitch is active E7 keyswitch (customer-specific signal for mode selection) 0 = E7 keyswitch is not active 1 = E7 keyswitch is active Issued: 12.08.2011 Version: BA KR C4 GI V4 en 72 / 179...
Page 73 The value 1 must be assigned to the input. Reserved 13 The value 1 must be assigned to the input. Reserved 14 The value 1 must be assigned to the input. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 73 / 179...
Page 74 1 = T2 mode is active The signal “Peri enabled” is set to 1 (active) if the following conditions are met: Signal “Peri enabled” Drives are activated.  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 74 / 179...
Page 75 SHS2 Safety stop 2 (all axes) 0 = Safety stop 2 is not active 1 = Safety stop 2 is active (safe state reached) Reserved 13 Reserved 14 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 75 / 179...
Page 76: Schematic Circuit Diagram Of Profisafe Enabling Switch
(e.g. in the case of a software update) and if this input is preset with the value 0, then the manipulator would either not move or would unex- pectedly come to a standstill. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 76 / 179...
Page 77 6 Planning KUKA recommends pre-assignment of the reserved inputs with 1. If a reserved input has a new safety function assigned to it, and the in- put is not used by the customer’s PLC, the safety function is not acti- vated.
Page 78 0 = safe operational stop is not active. 1 = safe operational stop is active. 6 … 7 Reserved 23 ... 24 Output byte 3 Signal Description 0 … 7 Reserved 25 ... 32 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 78 / 179...
Page 79: Ethercat Connection On The Cib
X65 can be found in the assembly and operating instructions of the optional KR C4 interfaces. The devices in the EtherCAT line must be configured with WorkVisu- Fig. 6-13: EtherCAT connection X44 EtherCAT connection X44 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 79 / 179...
Page 80: Pe Equipotential Bonding
Equipotential bonding from the start of the cable duct to the main equi- potential bonding Main equipotential bonding Equipotential bonding from the end of the cable duct to the main equi- potential bonding Issued: 12.08.2011 Version: BA KR C4 GI V4 en 80 / 179...
Page 81: Modifying The System Configuration, Exchanging Devices
A dual-channel acknowledge button must be installed outside the physical safeguard. The closing of the safety gate must be confirmed by pressing the acknowledge button before the industrial robot can be started again in Auto- matic mode. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 81 / 179...
Page 82: Performance Level
5 x 10 VKR C4 retrofit interface VKR C1, external EMERGENCY STOP and operator safety functions For controller variants that are not listed here, please contact KUKA Roboter GmbH. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 82 / 179...
Page 83: Transportation
2. Attach the lifting tackle to the crane. If the suspended robot controller is transported too quick- ly, it may swing and cause injury or damage. Transport the robot controller slowly. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 83 / 179...
Page 84: Transportation By Fork Lift Truck
The anti-toppling bracket must be fastened to the robot controller.  Procedure Fig. 7-3: Transportation by pallet truck Robot controller with anti-toppling bracket Robot controller in raised position Issued: 12.08.2011 Version: BA KR C4 GI V4 en 84 / 179...
Page 85: Transportation With The Set Of Rollers (Optional)
The robot controller must not be hitched to a ve- hicle and transported using its rollers. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 85 / 179...
Page 86 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 86 / 179...
Page 87: Start-Up And Recommissioning
Page 102) Start-up mode (>>> 8.12 "Start-up mode" Page 102) Switch on the robot controller. (>>> 8.13 "Switching on the robot controller" Page 103) Issued: 12.08.2011 Version: BA KR C4 GI V4 en 87 / 179...
Page 88: Installing The Robot Controller
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. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 88 / 179...
Page 89: Connecting The Standard Connecting Cables
4. Connect the peripheral cables. Fig. 8-1: Example: Installing the cables in the cable duct 1 Cable duct 4 Motor cables 2 Separating webs 5 Data cables 3 Welding cables Issued: 12.08.2011 Version: BA KR C4 GI V4 en 89 / 179...
Page 90: Standard Motor Cables, X20
KR C4 8.3.1 Standard motor cables, X20 Connector pin allocation Fig. 8-2: Connector pin allocation for X20 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 90 / 179...
Page 91: Motor Cables For Heavy-Duty Robot, X20.1 And X20.4
8 Start-up and recommissioning 8.3.2 Motor cables for heavy-duty robot, X20.1 and X20.4 Connector pin allocation Fig. 8-3: Connector pin allocation for X20.1 and X20.4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 91 / 179...
Page 92: Motor Cable For External Axis, X7.1 (Optional)
Motor cable for external axis, X7.2 (optional) The motor cable must not exceed a total length of 50 m. Connector pin allocation Fig. 8-5: Connector pin allocation X7.2 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 92 / 179...
Page 93: Data Cables, X21
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. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 93 / 179...
Page 94 KR C4 Fig. 8-7: Example: Installing the cables in the cable duct 1 Cable duct 4 Motor cables 2 Separating webs 5 Data cables 3 Welding cables Issued: 12.08.2011 Version: BA KR C4 GI V4 en 94 / 179...
Page 95: 5-Axis Heavy-Duty Palletizing Robot, Motor Cables X20.1 And X20.4
8 Start-up and recommissioning 8.4.1 5-axis heavy-duty palletizing robot, motor cables X20.1 And X20.4 Connector pin allocation Fig. 8-8: 5-axis palletizing robot, connector pin allocation X20.1 and X20.4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 95 / 179...
Page 96: 4-Axis Heavy-Duty Palletizing Robot, Motor Cables X8
KR C4 8.4.2 4-axis heavy-duty palletizing robot, motor cables X8 Connector pin allocation Fig. 8-9: 4-axis heavy-duty palletizing robot, connector pin allocation X8 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 96 / 179...
Page 97: 5-Axis Palletizing Robot, Motor Cables X20
8 Start-up and recommissioning 8.4.3 5-axis palletizing robot, motor cables X20 Connector pin allocation Fig. 8-10: 5-axis palletizing robot, connector pin allocation X20 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 97 / 179...
Page 98: 4-Axis Palletizing Robot, Motor Cables X20
Fig. 8-11: 4-axis palletizing robot, connector pin allocation X20 8.4.5 Palletizing robot motor cable for external axis, X7.1 and X7.2 The motor cable must not exceed a total length of 50 m. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 98 / 179...
Page 99: Fastening The Kuka Smartpad Holder (Optional)
(>>> 6.4 "Fastening the KUKA smartPAD holder (optional)" Page 63) Plugging in the KUKA smartPAD Plug the KUKA smartPAD to X19 on the robot controller. Procedure  If the smartPAD is disconnected, the system can no lon- ger be switched off by means of the EMERGENCY STOP button on the smartPAD.
Page 100: Connecting The Pe Equipotential Bonding
Electrical voltage can cause physical injuries. The robot controller may only be operated with grounded-neutral power supply systems. Fig. 8-14: Connector pin allocation X1 N* Option for service socket Robot controller is switched off. Precondition  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 100 / 179...
Page 101: Reversing The Battery Discharge Protection Measures
Connector X11 may only be plugged in or unplugged when the robot controller is switched off. If connector X11 is plugged in or unplugged when energized, damage to property may oc- cur. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 101 / 179...
Page 102: System Configuration Of The Industrial Robot Modified
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.  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 102 / 179...
Page 103: Switching On The Robot Controller
1. Switch on the mains power to the robot controller. Procedure 2. Unlock the EMERGENCY STOP button on the KUKA smartPAD. 3. Switch on the main switch. The control PC begins to run up the operating system and the control software.
Page 104 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 104 / 179...
Page 105: Operation
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 documentation for the smartPAD.
Page 106 Displays the keyboard. It is generally not necessary to press this key to display the keyboard, as the smartHMI detects when key- board input is required and displays the keyboard automatically. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 106 / 179...
Page 107: Rear View
In the operating modes Automatic and Automatic Exter- nal, the enabling switch has no function. The USB connection is used, for example, for archiving USB connec- and restoring data. tion Only for FAT32-formatted USB sticks. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 107 / 179...
Page 108 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 108 / 179...
Page 109: Maintenance
This mains voltage can cause life- threatening injuries on contact. The power cable is de-energized.  Observe the ESD guidelines.  Fig. 10-1: Maintenance points Issued: 12.08.2011 Version: BA KR C4 GI V4 en 109 / 179...
Page 110: Checking Sib Relay Outputs
1. Set operating mode to Automatic or Automatic External. Procedure 2. Open operator safety (safeguard). 3. Release enabling switch in “T1” or “T2” mode. If no error message is displayed, the relay outputs are OK. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 110 / 179...
Page 111: Checking Extended Sib Relay Outputs
2. Clean robot controller with a cloth soaked with a mild cleaning agent. 3. Clean cables, plastic parts and hoses with a solvent-free cleaning agent. 4. Replace damaged, illegible or missing inscriptions, labels and plates. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 111 / 179...
Page 112 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 112 / 179...
Page 113: Repair
Repair 11.1 Repair and procurement of spare parts Repairs to the robot controller may only be carried out by KUKA customer sup- Repair port personnel or by customers who have taken part in a relevant course of training held by KUKA Roboter GmbH.
Page 114 Fastening of cable inlet Cover of the cable inlet 5. Remove the fan holder together with the fan. 6. Install the new fan together with its holder and fasten. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 114 / 179...
Page 115: Control Pc
10. Plug in fan connector X14 on the CCU. 11.3 Control PC Overview Fig. 11-4: Overview of the control PC Hard drive Processor heat sink Motherboard PC fan PC interfaces PC power supply unit Issued: 12.08.2011 Version: BA KR C4 GI V4 en 115 / 179...
Page 116 PCI2 Field bus PCIe16 LAN Dual NIC PCIe1 Not assigned PCIe16 GK (optional) PCI3 Field bus PCIe4 Not assigned The following components are located on the motherboard: Motherboard Issued: 12.08.2011 Version: BA KR C4 GI V4 en 116 / 179...
Page 117: Exchanging The Control Pc
PC interfaces, on-board network and USB PC slots SATA connections 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.
Page 118: Exchanging The Control Pc Fan
Control PC housing Fan grille 4. Remove outer fan grille. 5. Pull the fan inwards off the mounting plugs. 6. Remove the expanding rivets and take off the fan grille. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 118 / 179...
Page 119 8. Install the mounting plugs in the fan. 9. Insert the fan into the PC housing and pull the mounting plugs through the PC housing. 10. Reattach fan grille. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 119 / 179...
Page 120: Exchanging The Motherboard
5. Plug in the SATA and power supply connectors 6. Fasten the hard drive with the knurled screws. 7. Install the operating system and the KUKA System Software (KSS). 8. The system configuration of the industrial robot must be configured using WorkVisual.
Page 121: Modifying The System Configuration, Exchanging Devices
The interchanging of 2 identical devices can only occur in the case of the KSP3x40 if the current system configuration contains 2 KSP3x40. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 121 / 179...
Page 122: Exchanging The Kuka Power Pack
White cables remain under mains voltage even with the main switch turned off! This mains voltage can cause life- threatening injuries on contact. Observe the ESD guidelines.  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 122 / 179...
Page 123 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. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 123 / 179...
Page 124: Exchanging The Kuka Servo Pack
Fig. 11-16: KSP connection with amplifiers for 3 axes Item Connector Description Brakes power supply OUT Drive bus OUT Control electronics power supply OUT DC link OUT DC link IN Control electronics power supply IN Issued: 12.08.2011 Version: BA KR C4 GI V4 en 124 / 179...
Page 125 1. Unlock connectors X20 and X21 of the data cables. Unplug all connections Procedure to the KSP. Unplugging the data cable connectors without first un- locking them damages the connectors. Unlock the con- nectors before unplugging them. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 125 / 179...
Page 126 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. Fig. 11-18: KSP fastening Issued: 12.08.2011 Version: BA KR C4 GI V4 en 126 / 179...
Page 127: Exchanging The Cabinet Control Unit
KUKA Operator Panel Interface KCP (yellow) KUKA System Bus, KPC (rot) EtherCAT Interface (KUKA Extension Bus) (red) Spare (yellow) KUKA System Bus, RoboTeam (green) KUKA System Bus, RoboTeam (orange) Issued: 12.08.2011 Version: BA KR C4 GI V4 en 127 / 179...
Page 128 1. Unlock the data cable connectors. Unplug all connections to the CCU. Procedure Unplugging the data cable connectors without first un- locking them damages the connectors. Unlock the con- nectors before unplugging them. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 128 / 179...
Page 129 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. Fig. 11-21: CCU fastening Tabs Fastening screw Issued: 12.08.2011 Version: BA KR C4 GI V4 en 129 / 179...
Page 130: Exchanging The Safety Interface Board
Power supply for additional components X252 Safe outputs X253 Safe inputs X254 Safe inputs X258 KUKA System Bus IN X259 KUKA System Bus OUT Extended connections Fig. 11-23: Extended SIB connections Issued: 12.08.2011 Version: BA KR C4 GI V4 en 130 / 179...
Page 131 Procedure Unplugging the data cable connectors without first un- locking them damages the connectors. Unlock the con- nectors before unplugging them. Fig. 11-24: Unlocking the data cable connectors Issued: 12.08.2011 Version: BA KR C4 GI V4 en 131 / 179...
Page 132 5. If exchanging the SIB resulted in a system modification, the system con- figuration of the industrial robot must be configured using WorkVisual. Fig. 11-25: SIB with fastening plate Fastening screw Tabs Issued: 12.08.2011 Version: BA KR C4 GI V4 en 132 / 179...
Page 133: Exchanging The Resolver Digital Converter
This mains voltage can cause life- threatening injuries on contact. Observe the ESD guidelines.  1. Remove the screws from the lid of the RDC box. Procedure Issued: 12.08.2011 Version: BA KR C4 GI V4 en 133 / 179...
Page 134 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. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 134 / 179...
Page 135: Exchanging The Batteries
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. 6. Remove the Velcro strip. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 135 / 179...
Page 136 9. Fasten the battery blocks with the Velcro strip. 10. Install the cooling duct and screw it firmly in place. Storage Issued: 12.08.2011 Version: BA KR C4 GI V4 en 136 / 179...
Page 137: Exchanging The Low-Voltage Power Supply Unit
11.7 Exchanging the pressure relief plug The pressure relief plug is used to generate an overpressure inside the cabi- Description net. This prevents excessive fouling of the cabinet. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 137 / 179...
Page 138: Installing The Kuka System Software (Kss)
Foam ring Filter insert 11.8 Installing the KUKA System Software (KSS) Further information is contained in the operating and programming in- structions for the KUKA System Software (KSS). Issued: 12.08.2011 Version: BA KR C4 GI V4 en 138 / 179...
Page 139: Troubleshooting
X310, X312. For test pur- poses, disconnect the cables at X309, X310, X312 and switch the controller off and back on again. If the error recurs, exchange the module. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 139 / 179...
Page 140 Green Off = no supply voltage Check infeed at X1. present Voltage, On = power supply present Power Sup- ply 3 (long- duration bat- tery backup) Issued: 12.08.2011 Version: BA KR C4 GI V4 en 140 / 179...
Page 141 CCU module Flashing at 1 Hz = normal state Flashing at 10 Hz = boot phase Flashing = fault code (inter- Exchange CCU module nal) Issued: 12.08.2011 Version: BA KR C4 GI V4 en 141 / 179...
Page 142 Off = Init (after switching on) ATμC I/O node Flashing at 2.5 Hz = Pre-Op (intermediate state on startup) Single signal = Safe Op 10 Hz = boot (for firmware update) Issued: 12.08.2011 Version: BA KR C4 GI V4 en 142 / 179...
Page 143: Cabinet Control Unit Fusing
CCU safe inputs F17.3 CCU logic F306 SmartKCP supply F302 SIB power supply F3.2 KPP1 logic without battery 7.5 A backup F3.1 KPP1 brakes without battery 15 A backup Issued: 12.08.2011 Version: BA KR C4 GI V4 en 143 / 179...
Page 144: Resolver Digital Converter Led Display
EtherCAT AT bus Flashing at 2.5 Hz = Pre-Op  Single signal = Safe Op  Flashing = fault code (internal)  Flashing at 10 Hz = boot  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 144 / 179...
Page 145: Controller System Panel Led Display
Flashing = fault code (internal)  12.4 Controller System Panel LED display Overview Fig. 12-4 Item Designation Description LED1 Operating LED LED2 Sleep LED LED3 Automatic LED LED4 Error LED Issued: 12.08.2011 Version: BA KR C4 GI V4 en 145 / 179...
Page 146: Controller System Panel Led Error Display
ProfiNet ping is being executed 12.5 Controller System Panel LED error display Overview Fig. 12-5 Item Designation Description LED1 Operating LED LED2 Sleep LED LED3 Automatic LED LED4 Error LED Issued: 12.08.2011 Version: BA KR C4 GI V4 en 146 / 179...
Page 147: Lan Onboard Led Display
On = connection established  Flashing = connection active  Speed Yellow/ Off = 10 Mb  green Green = 100 Mb  Yellow = 1000 Mb  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 147 / 179...
Page 148: Safety Interface Board Led Display
Off = Init (after switching on) Safety nodes Flashing at 2.5 Hz = Pre-Op (intermediate state on startup) Single signal = Safe Op Flashing at 10 Hz = boot (for firmware update) Issued: 12.08.2011 Version: BA KR C4 GI V4 en 148 / 179...
Page 149 SIB board Fuse LED On = fuse defective Exchange defective fuse Off = fuse OK The LED indi- cates the sta- tus of the fuse Issued: 12.08.2011 Version: BA KR C4 GI V4 en 149 / 179...
Page 150 Green On = supply voltage present Off = no supply voltage Check fuse F302  present If the LED PWR +3V3  lights up, exchange the SIB board Issued: 12.08.2011 Version: BA KR C4 GI V4 en 150 / 179...
Page 151: Safety Interface Board Fuses
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. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 151 / 179...
Page 152 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 152 / 179...
Page 153: Checking The Kuka Servo Pack
LED group: axis control LED group: drive bus status Device status Red LED Green LED Meaning No power supply to the control elec- tronics Fault in the KSP Issued: 12.08.2011 Version: BA KR C4 GI V4 en 153 / 179...
Page 154: Checking The Kuka Power Pack
1. Check power supply LED group. Procedure 2. Check drive bus status LED group. 3. Check KSP device status LED group. 4. Check axis control LED group. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 154 / 179...
Page 155 Fault in the axis Flashing No servo enable Servo enable Drive bus Yellow LED Green LED Meaning No power supply to the control elec- tronics Fault in power supply Issued: 12.08.2011 Version: BA KR C4 GI V4 en 155 / 179...
Page 156: Kpp And Ksp Error Messages
Check motor  current of the KPP Check motor cable  (short-circuit,…) Reinitialize the drive bus:  Power Off / Power On Check KSP  Check KPP  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 156 / 179...
Page 157: Troubleshooting
Dirt in cooling circuit => clean  Check PC fan  Reinitialize the drive bus:  Power Off / Power On Check KSP  Check KPP  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 157 / 179...
Page 158 Mains voltage too high  ing charging, Too few capacitors connected  KPP/KSP (axis) (too few modules) Reinitialize the drive bus:  Power Off / Power On Check KPP  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 158 / 179...
Page 159: Kpp And Ksp Warning Messages
Device state: OK 26103 Internal error, The device has Reinitialize the drive bus:  KPP/KSP (axis) detected an internal Power Off / Power On error. Check KPP (see LEDs)  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 159 / 179...
Page 160 Check mains voltage  (axis) Check intermediate circuit ca-  bling Reinitialize the drive bus:  Power Off / Power On Check KSP  Check KPP charging circuit  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 160 / 179...
Page 161 KPP/KSP on the controller bus Power Off / Power On (axis) Check EtherCat cabling  Check EtherCat stack  Check CCU  Check KPP  Check KSP  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 161 / 179...
Page 162 KSP (axis) Check ballast resistor  Check cabling between KPP  and ballast resistor Reinitialize the drive bus:  Power Off / Power On Check KPP  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 162 / 179...
Page 163 / short-circuit / Check brake cable / motor ca-  overcurrent / no brake connected Reinitialize the drive bus:  Power Off / Power On Check KSP  Issued: 12.08.2011 Version: BA KR C4 GI V4 en 163 / 179...
Page 164 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 164 / 179...
Page 165: Decommissioning, Storage And Disposal
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. Issued: 12.08.2011 Version: BA KR C4 GI V4 en 165 / 179...
Page 166 Dispose of without dis- mantling Steel (ST 52-3) Allen screws, washers Cable ties Electrical components Bus modules, boards, Dispose of as electri- sensors cal scrap without dis- assembling Issued: 12.08.2011 Version: BA KR C4 GI V4 en 166 / 179...
Page 167: Kuka Service
Description of the problem, duration and frequency of the fault  14.2 KUKA Customer Support KUKA Customer Support is available in many countries. Please do not hesi- Availability tate to contact us if you have any questions. Ruben Costantini S.A. (Agency)
Page 168 Tel. +86 21 6787-1808 Fax +86 21 6787-1805 info@kuka-sha.com.cn www.kuka.cn KUKA Roboter GmbH Germany Zugspitzstr. 140 86165 Augsburg Germany Tel. +49 821 797-4000 Fax +49 821 797-1616 info@kuka-roboter.de www.kuka-roboter.de Issued: 12.08.2011 Version: BA KR C4 GI V4 en 168 / 179...
Page 169 KUKA Robotics Korea Co. Ltd. Korea 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 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 169 / 179...
Page 170 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 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 170 / 179...
Page 171 Spain Pol. Industrial Torrent de la Pastera Carrer del Bages s/n 08800 Vilanova i la Geltrú (Barcelona) Spain Tel. +34 93 8142-353 Fax +34 93 8142-950 Comercial@kuka-e.com www.kuka-e.com Issued: 12.08.2011 Version: BA KR C4 GI V4 en 171 / 179...
Page 172 Fax +420 22 62 12 27 0 support@kuka.cz KUKA Robotics Hungaria Kft. Hungary Fö út 140 2335 Taksony Hungary Tel. +36 24 501609 Fax +36 24 477031 info@kuka-robotics.hu Issued: 12.08.2011 Version: BA KR C4 GI V4 en 172 / 179...
Page 173 Tel. +1 866 8735852 Fax +1 586 5692087 info@kukarobotics.com www.kukarobotics.com KUKA Automation + Robotics Hereward Rise Halesowen B62 8AN Tel. +44 121 585-0800 Fax +44 121 585-0900 sales@kuka.co.uk Issued: 12.08.2011 Version: BA KR C4 GI V4 en 173 / 179...
Page 174 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 174 / 179...
Page 175: Index
Controller System Panel LED display 145 Exchanging devices 81, 121 Controller System Panel LED error display 146 Exchanging the hard drive 120 Cooling circuits 21 Extended SIB, connections 130 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 175 / 179...
Page 176 KSB configuration variants 18 Motor cables, heavy-duty robot 91, 96 KSB devices 18 Motor cables, X20 90 KSI 8 Mounting plate for customer components 22 KSP 8, 13 Mouse, external 49 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 176 / 179...
Page 177 Start-up overview 87 Resolver Digital Converter 15 STOP 0 36, 38 Resolver Digital Converter, exchange 133 STOP 1 36, 38 Resolver Digital Converter, LED display 144 STOP 2 36, 38 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 177 / 179...
Page 178 Use, improper 35 User 37, 38 Velocity monitoring 45 Vibration resistance 26 Warnings 7 Working range limitation 46 Workspace 37, 39, 40 X11, configuring 101 X19 connector pin allocation 100 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 178 / 179...
Page 179 KR C4 Issued: 12.08.2011 Version: BA KR C4 GI V4 en 179 / 179...

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