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KR C2 edition05
Operating Instructions Manual
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Kuka KR C2 edition05 Operating Instructions Manual

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KUKA Robot Group Controller
KR C2 edition05
Operating Instructions
Issued: 11.07.2007 Version: 3.3
V3.3 11.07.200
Industrial automation
Elincom
European
Russia: www.elinc.ru
Union:www.hmi4u.com
KR C2 edition05
© Copyright 2007
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 the KUKA ROBOT GROUP.
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, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS4-DOC
V0.4 22.03.2006 pub de
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Contents
Contents
1 Introduction ...................................................................................................... 9
1.1 Target group ................................................................................................................... 9
1.2 Robot system documentation ......................................................................................... 9
1.3 Representation of warnings and notes ........................................................................... 9
1.4 Terms used ..................................................................................................................... 9
2 Product description ......................................................................................... 11
2.1 Overview of the robot system ......................................................................................... 11
2.2 Overview of the robot controller ...................................................................................... 11
2.3 Description of the control PC .......................................................................................... 12
2.3.1 PC interfaces .............................................................................................................13
2.3.2 PC slot assignment .................................................................................................... 14
2.3.3 Motherboard .............................................................................................................. 15
2.3.4 Hard drive .................................................................................................................. 16
2.3.5 CD-ROM drive (optional) ........................................................................................... 16
2.3.6 Floppy disk drive (optional) ........................................................................................ 16
2.3.7 Multi-function card (MFC3) ........................................................................................ 16
2.3.8 Digital servo-electronics (DSE-IBS-C33) ................................................................... 18
2.3.9 KUKA VGA card (KVGA) ........................................................................................... 18
2.3.10 Batteries .................................................................................................................... 19
2.4 Description of the KUKA Control Panel (KCP) ............................................................... 19
2.4.1 Front view .................................................................................................................. 20
2.4.2 Rear view ................................................................................................................... 21
2.5 KCP coupler (optional) .................................................................................................... 21
2.6 Electronic Safety Circuit (ESC) safety logic .................................................................... 23
2.6.1 ESC nodes ................................................................................................................ 24
2.6.2 Overview of CI3 boards ............................................................................................. 25
2.6.3 CI3 Standard board ................................................................................................... 26
2.6.4 CI3 Extended board ................................................................................................... 28
2.6.5 CI3 Bus board ............................................................................................................ 29
2.6.6 CI3 Tech board .......................................................................................................... 31
2.7 Description of the power unit .......................................................................................... 32
2.7.1 Power supply unit KPS 600 ....................................................................................... 33
2.7.2 Fuses ......................................................................................................................... 35
2.7.3 Low-voltage power supply KPS-27 ............................................................................ 36
2.7.4 KUKA Servo Drive (KSD) .......................................................................................... 36
2.7.5 Mains filter ................................................................................................................. 38
2.8 Cabinet cooling ............................................................................................................... 38
2.9 Description of interfaces ................................................................................................. 39
2.9.1 Power supply connection X1/XS1 .............................................................................. 40
2.9.2 KCP connector X19 ................................................................................................... 42
2.9.3 Motor connector X20, axes 1 to 6 .............................................................................. 43
2.9.4 Motor connector X7 (optional) ................................................................................... 44
2.9.5 Data cable X21, axes 1 to 8 ....................................................................................... 45
2.10 Description of the mounting plate for customer components (optional) .......................... 45
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3 Technical data .................................................................................................. 47
3.1 Basic data ....................................................................................................................... 47
3.2 KCP coupler (optional) .................................................................................................... 48
3.3 Dimensions of robot controller ........................................................................................ 49
3.4 Minimum clearances, robot controller ............................................................................. 49
3.5 Minimum clearances, top-mounted / technology cabinet ................................................ 50
3.6 Swing range for cabinet door .......................................................................................... 50
3.7 Plates and labels ............................................................................................................ 50
4 Safety ................................................................................................................ 53
4.1 System planning .............................................................................................................53
4.1.1 EC declaration of conformity and declaration of incorporation .................................. 53
4.1.2 Installation site ........................................................................................................... 53
4.1.3 External safeguards ................................................................................................... 53
4.1.4 Workspace, safety zone and danger zone ................................................................ 54
4.2 Description ...................................................................................................................... 55
4.2.1 Category of the safety-oriented circuits ..................................................................... 55
4.2.2 Stop reactions ............................................................................................................55
4.2.3 Labeling on the robot system ..................................................................................... 56
4.2.4 Safety information ...................................................................................................... 56
4.3 Safety features ................................................................................................................ 57
4.3.1 Overview of the safety features ................................................................................. 57
4.3.2 ESC safety logic ........................................................................................................ 57
4.3.3 Operator safety input ................................................................................................. 57
4.3.4 EMERGENCY STOP button ...................................................................................... 58
4.3.5 Enabling switches ...................................................................................................... 58
4.3.6 Jog mode ................................................................................................................... 59
4.3.7 Mechanical end stops ................................................................................................ 59
4.3.8 Mechanical axis range limitation (option) ................................................................... 59
4.3.9 Axis range monitoring (option) ................................................................................... 60
4.3.10 Software limit switches .............................................................................................. 60
4.3.11 Release device (option) ............................................................................................. 60
4.3.12 KUKA.SafeRobot (option) .......................................................................................... 61
4.4 Personnel ........................................................................................................................ 61
4.5 Safety measures .............................................................................................................62
4.5.1 General safety measures ........................................................................................... 62
4.5.2 Transportation ............................................................................................................63
4.5.3 Start-up ...................................................................................................................... 63
4.5.4 Programming ............................................................................................................. 64
4.5.5 Automatic mode ......................................................................................................... 64
5 Planning ............................................................................................................ 65
5.1 Overview of planning ...................................................................................................... 65
5.2 Electromagnetic compatibility (EMC) .............................................................................. 65
5.3 Installation conditions .....................................................................................................66
5.4 Connection conditions .................................................................................................... 67
5.5 Power supply connection ................................................................................................ 68
5.5.1 Power supply connection via X1 Harting connector .................................................. 69
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5.5.2 Power supply connection via CEE connector XS1 .................................................... 69
5.6 EMERGENCY STOP circuit and safeguard ................................................................... 70
5.7 Interface X11 .................................................................................................................. 71
5.8 PE equipotential bonding ................................................................................................ 74
5.9 Planning the KCP coupler option .................................................................................... 75
6 Transportation .................................................................................................. 77
6.1 Transportation using lifting tackle ................................................................................... 77
6.2 Transportation by pallet truck ......................................................................................... 78
6.3 Transportation by fork lift truck ....................................................................................... 78
7 Start-up ............................................................................................................. 79
7.1 Start-up overview ............................................................................................................ 79
7.2 Installing the robot controller ........................................................................................... 80
7.3 Connecting the connecting cables .................................................................................. 80
7.4 Connecting the KCP ....................................................................................................... 81
7.5 Connecting the PE equipotential bonding ....................................................................... 81
7.6 Connecting the robot controller to the power supply ...................................................... 81
7.7 Reversing the battery discharge protection measures ................................................... 82
7.8 Connecting the EMERGENCY STOP circuit and safeguard .......................................... 82
7.9 Configuring and connecting connector X11 .................................................................... 82
7.10 Switching on the robot controller .................................................................................... 82
7.11 Checking the direction of rotation of the external fan ..................................................... 83
Contents
8 Operation .......................................................................................................... 85
8.1 Display and operator control elements of the KCP coupler (optional) ............................ 85
8.1.1 Uncoupling the KCP .................................................................................................. 85
8.1.2 Coupling the KCP ...................................................................................................... 85
8.2 Booting the robot controller from a USB stick ................................................................. 86
9 Maintenance ..................................................................................................... 87
9.1 Maintenance table .......................................................................................................... 87
9.2 Cleaning the robot controller ........................................................................................... 88
10 Repair ................................................................................................................ 89
10.1 Service jumper plug X11 ................................................................................................. 89
10.2 Exchanging the internal fan ............................................................................................ 90
10.3 Exchanging the external fan ........................................................................................... 91
10.4 Exchanging the pressure relief plug ............................................................................... 91
10.5 Exchanging the PC ......................................................................................................... 92
10.6 Exchanging the PC fans ................................................................................................. 93
10.7 Exchanging the motherboard battery .............................................................................. 94
10.8 Exchanging the motherboard .......................................................................................... 94
10.9 Exchanging DIMM memory modules .............................................................................. 94
10.10 Exchanging the batteries ................................................................................................ 95
10.11 Removal and installation of the CD-ROM drive (optional) .............................................. 96
10.12 Removal and installation of the floppy disk drive (optional) ............................................ 97
10.13 Exchanging the hard drive .............................................................................................. 98
10.14 Exchanging the KVGA card ............................................................................................ 98
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10.14.1 KVGA card settings ................................................................................................... 99
10.15 Exchanging the MFC3 card ............................................................................................ 99
10.16 Exchanging the DSE-IBS-C33 card ................................................................................ 99
10.17 Exchanging the KPS600 ................................................................................................. 100
10.18 Exchanging the KPS-27 .................................................................................................. 100
10.19 Exchanging the KSD ....................................................................................................... 101
10.20 Removal and installation of the KCP coupler ................................................................. 102
10.21 Installing the KUKA System Software (KSS) ................................................................. 102
11 Troubleshooting ............................................................................................... 103
11.1 Repair and procurement of spare parts .......................................................................... 103
11.2 PC fault profiles .............................................................................................................. 103
11.3 MFC3 error messages .................................................................................................... 105
11.4 KCP error messages ...................................................................................................... 105
11.5 Field bus communication error messages ...................................................................... 106
11.6 Fuses and LED indicators on the CI3 board ................................................................... 106
11.6.1 CI3 Standard board ................................................................................................... 106
11.6.2 CI3 Extended board ................................................................................................... 108
11.6.3 CI3 Bus board ............................................................................................................ 109
11.6.4 CI3 Tech board .......................................................................................................... 110
11.7 KPS 600 fuses, messages and error displays ................................................................ 112
11.8 KPS-27 error messages ................................................................................................. 115
11.9 Error messages on the KSD ........................................................................................... 115
11.10 KCP coupler LED display (optional) ............................................................................... 117
11.11 KCP coupler troubleshooting .......................................................................................... 119
11.12 DSE-RDW diagnosis ...................................................................................................... 120
11.12.1 Description of the user interface ................................................................................ 120
11.12.2 Setting the language .................................................................................................. 121
11.12.3 MFC3 register display ................................................................................................ 121
11.12.4 DSE IBS information .................................................................................................. 122
11.12.5 RDC table .................................................................................................................. 123
11.12.6 RDC offset and symmetry adjustment ....................................................................... 124
11.12.7 Check RDC-DSE communication .............................................................................. 125
11.12.8 Drive bus diagnostics ................................................................................................. 127
11.12.9 Drive bus error list ...................................................................................................... 128
11.12.10 Drive bus - KPS ......................................................................................................... 128
11.12.11 Drive bus - KSD-16 .................................................................................................... 130
11.12.12 KPS600 error messages ............................................................................................ 131
11.12.13 KSD error messages ................................................................................................. 132
11.13 ESC diagnosis ................................................................................................................ 132
11.13.1 User interface ............................................................................................................ 132
11.13.2 Log file ....................................................................................................................... 133
11.13.3 ESC circuit reset ........................................................................................................ 133
11.13.4 Terminating ESC diagnosis ....................................................................................... 133
11.13.5 State display of the ESC nodes ................................................................................. 134
11.13.6 Error display of the ESC nodes ................................................................................. 135
11.13.7 Displaying all status bits ............................................................................................ 136
11.13.8 Configuring controllers ............................................................................................... 137
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11.13.9 Configuring the controller properties .......................................................................... 138
11.13.10 Configuring ESC nodes ............................................................................................. 139
11.13.11 Selecting the display for signals ................................................................................ 140
11.13.12 Selecting the properties of the ESC node .................................................................. 141
11.13.13 Assigning ESC nodes to a controller ......................................................................... 142
11.13.14 Error messages and troubleshooting ......................................................................... 142
12 Appendix ........................................................................................................... 145
13 KUKA Service ................................................................................................... 147
13.1 Requesting support ......................................................................................................... 147
13.2 KUKA Customer Support ................................................................................................ 147
Index .................................................................................................................. 153
Contents
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1Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of electrical and electronic systems Advanced knowledge of the robot controller Advanced knowledge of the Windows operating system
For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training pro­gram can be found at www.kuka.com or can be obtained directly from our subsidiaries.

1.2 Robot system documentation

The robot system documentation consists of the following parts:
Operating instructions for the robot Operating instructions for the robot controller Operating and programming instructions for the KUKA System Software Documentation relating to options and accessories
1. Introduction
Each of these sets of instructions is a separate document.

1.3 Representation of warnings and notes

Safety Warnings marked with this pictogram are relevant to safety and must be ob-

served.
Danger!
This warning means that death, severe physical injury or substantial material damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.

Notes Notes marked with this pictogram contain tips to make your work easier or ref-

erences to further information.
Tips to make your work easier or references to further information.

1.4 Terms used

Term Description
DSE Digital Servo Electronics EMC Electromagnetic compatibility
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Term Description
KCP Teach pendant (KUKA Control Panel) KRL KUKA Robot Language KSS KUKA System Software MFC3 Multi-function card RDC Resolver Digital Converter RoboTeam A number of robots whose continuous path
motions are synchronized, or both synchronized and geometrically coordinated
SafeRobot Software and hardware components to replace
conventional axis range monitoring systems
USB Universal Serial Bus. Bus system for connecting
additional devices to a computer.
VxWorks Real-time operating system
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2 Product description

2.1 Overview of the robot system

A robot system consists of the following components:
Robot Robot controller KCP teach pendant Connecting cables Software Options, accessories
2. Product description
Fig. 2-1: Example of a robot system
1 Robot 3 Robot controller 2 Connecting cables 4 Teach pendant (KCP)

2.2 Overview of the robot controller

The robot controller is used for controlling the following systems:
KUKA robots KMC External kinematic system
The robot controller consists of the following components:
Control PC Power unit KCP teach pendant Safety logic ESC Connection panel
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Fig. 2-2: Overview of the robot controller
1 Power unit 4 Connection panel 2 Control PC 5 Mounting plate for customer
components
3 Safety logic (ESC) 6 KCP

2.3 Description of the control PC

Functions With its fitted components, the PC performs all the functions of the robot con-

troller.
Windows user interface with visual display and input Program creation, correction, archiving, and maintenance Sequence control Path planning Control of the drive circuit Monitoring Parts of the ESC safety circuit Communication with external periphery (other controllers, host computers,
PCs, network)

Overview The control PC includes the following components:

Motherboard with interfaces Processor and main memory Hard drive Floppy disk drive (optional) CD-ROM drive (optional) MFC3 KVGA DSE-IBS-C33 Batteries Optional modules, e.g. field bus cards
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2. Product description

2.3.1 PC interfaces

Overview

Fig. 2-3: Overview of the control PC
1 PC 4 Drives (optional) 2 PC interfaces 5 Batteries 3PC fan
Fig. 2-4: Control PC interfaces
Item Interface Item Interface
1 PCI slots 1 to 6
(>>> 2.3.2 "PC slot assign-
11 X961 power supply DC
24 V
ment" page 14)
2 AGP PRO slot 12 X801 DeviceNet (MFC3)
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Item Interface Item Interface
3 USB (2x) 13 ST5 serial real-time inter-
face COM 3 4 X804 Ethernet 14 ST6 ESC/KCP etc. 5 COM 1 serial interface 15 ST3 drive bus to KPS600 6 LPT1 parallel interface 16 ST4 serial RDC interface
X21 7 COM 2 serial interface 17 X805 KCP display (KVGA) 8 USB (2x) 18 X821 external monitor
(KVGA) 9 Keyboard connection 19 Slot 4 remains unassigned.
If a second DSE-IBS-C33
AUX card is plugged into
the MFC3, this overlaps slot
4.
10 Mouse connection 20 X2 DC inputs and outputs.
SSB interface to the CI3
board.
To activate the USB connections, the following BIOS settings must be made.
1. During the boot procedure, press F2 to switch to the BIOS.
2. In the Advanced menu, select the menu item Advanced Sys tem Config- uration.
3. Activate all menu items except USB Legacy Support.

2.3.2 PC slot assignment

Overview

Fig. 2-5: PCI slots
The PC slots can be fitted with the following plug-in cards:
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Slot Plug-in card
1
2
Interbus card (FOC) (optional) Interbus card (copper) (optional) LPDN scanner card (optional) Profibus master/slave card (optional) LPCN ControlNet card (optional) CN_EthernetIP card (optional)
LPDN scanner card (optional)
3 KVGA card 4 DSE-IBS-C33 AUX card (optional) 5MFC3 card 6
Network card (optional) LPDN scanner card (optional) Profibus master/slave card (optional) LIBO-2PCI card (optional) KUKA modem card (optional)
7free
2. Product description

2.3.3 Motherboard

Configuration The following components are located on the motherboard:

Processor Main memory (RAM) Interfaces to all PC components On-board network card BIOS
Fig. 2-6: Motherboard
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Connections

Item Element Item Element
1 External connections 13 External temperature sen-
sor 2 Fan 1 14 LCD control panel 3 RAM slot A 15 Fan 2 4 RAM slot B 16 Fan 3 5 Power ON II LED 17 FireWire (IEEE 1394) 6 Floppy disk drive 18 Housing monitoring 7 Power supply monitoring 19 USB G/H 8 Control panel 20 Serial AT A1 9 IDE drive 3/4 21 Serial AT A2
10 Power supply 22 USB E/F 11 IDE drive 1/2 23 Additional +3 V power sup-
ply
12 Jumpers 24 Additional +12 V power
supply
The KUKA Robot Group has assembled, tested and supplied the mother­board with an optimum configuration. No liability will be accepted for modifi­cations to the configuration that have not been carried out by the KUKA Robot Group.

2.3.4 Hard drive

Description The hard drive is partitioned into 2 "logical" drives. The 1st partition is ad-

dressed as C: and the 2nd as D:. The data cable is connected to the mother­board via connector IDE 1/2. The jumper must be connected in the "Master" position.
The following systems are available on the hard drive:
KSS KUKA System Software Windows XP Tech packages (optional)

2.3.5 CD-ROM drive (optional)

Description The CD-ROM drive is a device for reading CDs.

2.3.6 Floppy disk drive (optional)

Description The floppy disk drive is used for archiving data.

2.3.7 Multi-function card (MFC3)

Description 2 different MFC3 cards are used in the robot controller according to the spe-

cific customer requirements:
MFC3 Standard MFC3 Tech
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2. Product description
Fig. 2-7: MFC3 card

Connections

Item Connector Description
1 X2 Interface to the CI3 board 4 X801 CAN bus connection 5 X3 PC fan monitoring 6 X6 ESC, KCP-CAN, COM, user I/O 7 X8101 DSE connection

LEDs

Item LEDs Description
2 LED 2 DeviceNet CAN bus (two-color data bit
indication)
3 LED 1 DeviceNet CAN bus (two-color data bit
indication)

MFC3 Standard The MFC3 Standard card contains the system I/Os and has the following func-

tions:
RTAcc chip for VxWinRT (real-time function) DeviceNet connection
Customer-specific interface. The Multi-Power Tap option is recommended. As master circuit only.
Interface with the DSE
The MFC3 Standard card can accommodate a maximum of 2 DSE-IBS­C33 modules.
Interface to the CI3 safety logic Fan monitoring
Further information about the DeviceNet interface can be found in the corre­sponding KUKA documentation.
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MFC3 Tech The MFC3 Tech card contains the system I/Os and has the following func-

2.3.8 Digital servo-electronics (DSE-IBS-C33)

Description The DSE-IBS-C33 is plugged into the MFC3 and controls the servo modules.

Overview

tions:
All functions of the MFC3 Standard card Interface for the CR option (RoboTeam)
The MFC3 Tech card can only be used together with a CI3 Tech card.
Error and situation information read from the servo modules are also proc­essed.
If 2 RDCs are used in the robot system (in the case of more than 8 axes), each RDC must be fitted with a DSE-IBS-C33 board.

Connections

Item Connector Description
1 X4 Connection to the drive servos 2 X810 Connection to the MFC3
LED
Item LED Description
3 LED Flashes when the connection to the
MFC3 is established.

2.3.9 KUKA VGA card (KVGA)

Description The KCP is connected to the KVGA card. The resolution and the number of

colors (16 or 256) are set automatically during installation. There are 2 KCP connections on the KVGA card. A normal VGA monitor can also be connected in parallel.
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Fig. 2-8: KVGA card
2. Product description

Connections

Item Connector
1 External monitor connection 2 KCP connection

2.3.10 Batteries

Description The robot controller is provided with an uninterruptible 24 V power supply by

the batteries. The batteries ensure a controlled shutdown of the robot control­ler in the event of a power failure. They are backed up by the KPS600.
Fig. 2-9: Batteries

2.4 Description of the KUKA Control Panel (KCP)

Function The KCP (KUKA Control Panel) is the teach pendant for the robot system. The

KCP has all the functions required for operating and programming the robot system.
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2.4.1 Front view

Overview

Fig. 2-10: Front view of KCP
1 Mode selector switch 10 Numeric keypad 2 Drives ON 11 Softkeys 3 Drives OFF / SSB GUI 12 Start backwards key 4 EMERGENCY STOP button 13 Start key 5 Space Mouse 14 STOP key 6 Right-hand status keys 15 Window selection key 7 Enter key 16 ESC key 8 Arrow keys 17 Left-hand status keys 9 Keypad 18 Menu keys
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2.4.2 Rear view

Overview

2. Product description
Fig. 2-11: Rear view of KCP
1 Rating plate 4 Enabling switch 2 Start key 5 Enabling switch 3 Enabling switch

Description

Element Description Rating plate KCP rating plate Start key The Start key is used to start a program.
Enabling switch

2.5 KCP coupler (optional)

The enabling switch has 3 positions:
Not pressed Center position Panic position
The enabling switch must be held in the center posi­tion in operating modes T1 and T2 in order to be able
to jog the robot.
In the operating modes Automatic and Automatic Exter­nal, the enabling switch has no function.

Description The KCP coupler allows the KCP to be connected and disconnected with the

robot controller running.
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Overview

Fig. 2-12: KCP coupler LEDs and request button
1 Fault LED (red), KCP coupler 2 Request button with request LED (green)
Fig. 2-13: KCP coupler card

Connections

Item
Connect or
Description
1 X7 Request button LED connection 2 X5 ESC to the KCP 3 X20 SafeRobot to the KCP 4 X2 CI3 connection 5 X21 CAN bus to the KCP 6 X3 Debug connector B 7 X4 Debug connector A
The LEDs on the KCP coupler card indicate the operating status. (>>> 11.10 "KCP coupler LED display (optional)" page 117)
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2. Product description

2.6 Electronic Safety Circuit (ESC) safety logic

Overview The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer-

aided safety system. It permanently monitors all connected safety-relevant components. In the event of a fault or interruption in the safety circuit, the pow­er supply to the drives is shut off, thus bringing the robot system to a standstill.
The ESC system consists of the following components:
CI3 board KCP (master) KPS600 MFC (passive node)
The ESC system with its node periphery replaces all the interfaces of a con­ventional safety system.
The ESC safety logic monitors the following inputs:
Local EMERGENCY STOP External EMERGENCY STOP Operator safety Enabling Drives OFF Drives ON Operating modes Qualifying inputs
Fig. 2-14: Structure of the ESC circuit
1 KPS600 5 MFC3 2 CI3 board 6 DSE 3 KCP coupler (optional) 7 PC 4KCP

Node in the KCP The node in the KCP is the master and is initialized from here.

The node receives dual-channel signals from:
EMERGENCY STOP pushbutton
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Node in the KPS In the KPS there is an ESC node which switches off the drives contactor in the

Node on the MFC3 On the MFC3 board is a passive ESC node which monitors the information on

2.6.1 ESC nodes

Configuration Each node consists of two ESC chips (A and B), which monitor each other.

Enabling switches
The node receives single-channel signals from:
Drives ON AUTO mode, TEST mode
If no KCP coupler is used, the ESC circuit will only function with the KCP con­nected. If the KCP is unplugged during operation without a KCP coupler, the drives are immediately switched off.
case of a fault.
the ESC circuit and then passes it on to the controller.
Fig. 2-15: ESC nodes
Signal name
Meaning Description
TA Test output Pulsed voltage for the interface inputs. NA Local E-STOP Input for local E-STOP (dual-channel). If the
signal is interrupted, the drives contactor drops out immediately.
ENA External E-
STOP
Input for external E-STOP (dual-channel). If the signal is interrupted, the drives contactor drops out after a delay.
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2. Product description
Signal name
ZS1 Enabling
ZS2 Enabling

Meaning Description

Input for external enabling switch (dual-chan­switches on the KCP
nel, 1-step). If the signal is interrupted in Test
mode, the drives contactor drops out immedi-
ately. switches, panic
position
BA Operating mode
(A=Automatic, T=Test)
Inputs for external mode selector switch (sin-
gle-channel). If the Automatic and Test
modes are activated simultaneously, the
drives contactor drops out immediately.
AE Drives ON out-
put
Output for the drives contactor (dual-chan-
nel). The contactor is activated/deactivated
by setting the voltage to 24 V/0 V.
AF Drives enable Input for external drives enable (single-chan-
nel). If the signal is interrupted, the drives
contactor drops out immediately.
QE Qualifying input This signal is used for external axes or load-
ing stations. If the signal is interrupted in Test
mode, the drives contactor drops out immedi-
ately.
E2 Special keys-
­witch (customer­specific)
BS Operator safety Input for a safety gate safety switch (single-
channel). If the signal is interrupted, the drives contactor drops out after a delay; optionally also immediately.
AA Drives ON Input for Drives ON (single-channel). The
edge of the signal is evaluated. It is only pos­sible to activate the drives contactor with a positive edge at this input.
LNA Local E-STOP Output for local E-STOP (dual-channel). The
output is set if a local E-STOP has been trig­gered. With the relay variant, the contacts are opened in the event of a local E-STOP.
AAU-
TO/ AT-
EST
BA
Operating mode Output (single-channel). The corresponding
output is set depending on the operating mode. With the relay variant, the contact is closed if the corresponding operating mode has been selected.
Arrows pointing towards the ESC chip represent the input signals, while those pointing away from the ESC chip represent the outputs. The signal TA(A), TA(B) is the pulsed voltage that must be supplied to every input.

2.6.2 Overview of CI3 boards

Description The CI3 board links the individual nodes of the ESC system with the customer
interface being used.
Various different boards are used in the robot controller according to the spe­cific customer requirements:
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Board Own node Description
CI3 Standard
(>>> 2.6.3 "CI3 Standard
board" page 26)
CI3 Extended
(>>> 2.6.4 "CI3 Extend-
ed board" page 28)
CI3 Bus (>>> 2.6.5 "CI3
Bus board" page 29)
No Indicates the following states:
Local E-STOP
Yes Indicates the following states:
Operating modes Local E-STOP Drives ON
No Connecting board between the
ESC circuit and the SafetyBUS p from PILZ
CI3 Tech (>>> 2.6.6 "CI3
Tech board" page 31)
Yes This board is required for the
following components:
KUKA.RoboTeam KUKA.SafeRobot SafetyBUS Gateway Output to the top-mounted
cabinet (external axes)
Power supply to a 2nd RDC
via X19A
Indicates the following states:
Operating modes Local E-STOP Drives ON

2.6.3 CI3 Standard board

Description This board is used as standard in the robot controller and has no node of its

own. It connects the nodes that are present in the ESC circuit and distributes the signals to the individual interfaces. The "Local E-STOP" state is indicated via a relay. The ESC circuit can be reset using the reset button.
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2. Product description

Connections

Fig. 2-16: CI3 Standard board connections and relays
Item Designation Description
1 X18 Interface to MFC3 (CR safety signals)
(optional) 2 X2 KPS connection 3 X3 MFC connection 4 X19 Interface to the RoboTeam lamp (optional).
RDC power supply 5 X4 Connection of external mode selector
switches (optional) 6 X7 CAN connection, I/O board 7 X6 Internal/external power supply and ESC cir-
cuit 8 X5 KCP connection 9 X21 KCP power supply and KCP CAN
10 X22 Peripheral interface for inputs and outputs 11 X1 Internal 24 V power supply 14 X8 Connection of external controllers, E-STOP
button on control cabinet
15 X16 Internal interface 16 X12 Peripheral interface, outputs > 500 mA 17 X31 Connection: robot controller, internal fan

Relays

Item Designation Description
12 K4 Message: Local E-STOP 13 K3 Message: Local E-STOP
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Reset

Item Designation Description
18 KY1 ESC Reset button

2.6.4 CI3 Extended board

Description This board has its own node and is used to indicate the following states of the

ESC circuit:
Operating modes Drives ON Local E-STOP
The ESC circuit can be reset using the reset button.
Fig. 2-17: CI3 Extended board connections and relays

Connections

Item Designation Description
1 X18 Interface to MFC3 (CR safety signals)
(optional) 2 X2 KPS connection 3 X3 MFC connection 4 X19 Interface to the RoboTeam lamp (optional).
RDC power supply 5 X4 Connection of external mode selector
switches (optional) 6 X7 CAN connection, I/O board 7 X6 Internal/external power supply and ESC cir-
cuit 8 X5 KCP connection
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2. Product description
Item Designation Description
9 X21 KCP power supply and KCP CAN
10 X22 Peripheral interface for inputs and outputs 11 X1 Internal 24 V power supply 18 X31 Connection: robot controller, internal fan 19 X8 Connection of external controllers, E-STOP
button on control cabinet
20 X16 Internal interface 21 X12 Peripheral interface, outputs > 500 mA

Relays

Item Designation Description
12 K4 Message: Local E-STOP 13 K3 Message: Local E-STOP 14 K8 Message: Auto-Test 15 K7 Message: Auto-Test 16 K1 Message: Drives ON 17 K2 Message: Drives ON

Reset

Item Designation Description
22 KY1 ESC Reset button

2.6.5 CI3 Bus board

Description The SafetyBUS p Gateway board is plugged onto the CI3 bus board and con-

nects the ESC circuit with the SafetyBUS p manufactured by PILZ. The CI3 bus board does not have its own node.
The ESC circuit can be reset using the reset button.
Further information is contained in the "ESC Safety System with SafetyBUS p Gateway" documentation.
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Connections

Fig. 2-18: CI3 Bus board connections
Item Designation Description
1 X18 Interface to MFC3 (CR safety signals)
(optional) 2 X2 KPS connection 3 X3 MFC connection 4 X19 Interface to the RoboTeam lamp (optional).
RDC power supply 5 X4 Connection of external mode selector
switches (optional) 6 X7 CAN connection, I/O board 7 X6 Internal/external power supply and ESC cir-
cuit 8 X5 KCP connection 9 X21 KCP power supply and KCP CAN
10 X22 Peripheral interface for inputs and outputs 11 X1 Internal 24 V power supply 12 X8 Connection of external controllers, E-STOP
button on control cabinet
13 X16 Internal interface 14 X12 Peripheral interface, outputs > 500 mA 15 X31 Connection: robot controller, internal fan 16 X13 SafetyBUS Gateway interface (optional)

Reset

Item Designation Description
17 KY1 ESC Reset button
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2. Product description

2.6.6 CI3 Tech board

Description The CI3 Tech board has its own node and is needed for the following compo-

nents:
KUKA.RoboTeam (Shared Pendant) KUKA.SafeRobot SafetyBUS Gateway Output to the top-mounted cabinet (external axes) Power supply to a 2nd RDC via X19A
The following states of the ESC circuit are indicated:
Operating modes Drives ON Local E-STOP
The ESC circuit can be reset using the reset button (26).
The CI3 Tech board can only be used together with the MFC3 Tech card.

Connections

Fig. 2-19: CI3 Tech board connections and relays
Item Designation Description
1 X18 Interface to MFC3 (CR safety signals)
(optional) 2 X2 KPS connection 3 X3 MFC connection 4 X19 Interface to the RoboTeam lamp (optional).
RDC power supply
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Item Designation Description
5 X4 Connection of external mode selector
switches (optional) 6 X7 CAN connection, I/O board 7 X6 Internal/external power supply and ESC cir-
cuit 8 X5 KCP connection 9 X21 KCP power supply and KCP CAN
10 X20 Interface to selector switch in Shared Pen-
dant (optional)
11 X24 CR OUT interface 12 X25 CR IN interface 13 X22 Peripheral interface for inputs and outputs 14 X23 Safe RDC interface (optional) 15 X1 Internal 24 V power supply 22 X10 QE signals 23 X28 Multi-power tap (OUT1) (optional) 24 X27 Multi-power tap (DeviceNet on MFC)
(optional)
25 X29 Multi-power tap (OUT2) (optional) 26 X13 SafetyBUS Gateway interface (optional) 28 X19A 2nd RDC 29 X11 RoboTeam/E7 30 X26 KUKA Guiding Device (KGD) interface
(optional)
31 X12 Peripheral interface, outputs > 500 mA 32 X16 Internal interface 33 X8 Connection of external controllers, E-STOP
button on control cabinet
34 X31 Connection: robot controller, internal fan

Relays

Item Designation Description
16 K4 Message: Local E-STOP 17 K3 Message: Local E-STOP 18 K8 Message: Auto-Test 19 K7 Message: Auto-Test 20 K1 Message: Drives ON 21 K2 Message: Drives ON

Reset

Item Designation Description
27 KY1 ESC Reset button

2.7 Description of the power unit

Overview The power unit includes the following components:

Power supply units Servo drive modules (KSD) Fuse elements Fans Main switch
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Mains filter
Fig. 2-20: Power unit
2. Product description
1 Low-voltage power supply KPS-27 2 Fuse elements (24 V without battery back-up) 3 Mains filter 4 Main switch (EU version) 5 Fan for inner cooling circuit 6 Power supply unit KPS600 7 KSDs for 2 external axes (option) 8 KSDs for 6 robot axes 9 Fuse elements (24 V with battery back-up)

2.7.1 Power supply unit KPS 600

Description Via the drive bus, commands are received from the robot controller and status

messages are sent to the robot controller. Communication is monitored by means of a watchdog circuit. In the event of a failure, short-circuit braking is activated.
The KPS 600 contains:
Mains contactor Power unit with starting circuit Ballast circuit, including short-circuit braking relays Brake switches (in common for all 6 robot axes and separate for 2 external
axes)
Interface to DSE-IBS and servo drive modules Battery charging circuit, disconnection of the backup voltage, voltage dis-
tribution 24 V
Interbus monitoring Fan cutoff (output), fan monitoring (input) Interface with the safety logic Temperature monitoring of:
Heat sink
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24 V supply The following components are connected to the integrated 24 V power supply:

Intermediate circuit The KPS 600 supplies the energy to the intermediate circuit and includes:

Ballast resistor Control cabinet interior
Motor brakes Customer interface Control PC KSD
Rectifier circuit Charging circuit Ballast circuit Discharging circuit Main contactor K1
Fig. 2-21: Connections on the KPS 600

Connections

Item Connector Description
1 X7 24 V battery, KSD and controller 2 X8 Ballast resistor 3 X9 Energy recovery unit 4 X16 Energy recovery unit
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2. Product description
Item Connector Description
5 X-K1a Interface to the power board for the K1 auxiliary
contacts (internal) 6 X2 Control connections K1 7 X6 24 V from low-voltage power supply 8 X123 User interface 9 X110 Fan/resistor monitoring
10 X114 Additional inputs to the control board 11 X121 Interbus input 12 X122 Interbus output 13 X14 ESC 14 X12 Motor holding brake 15 X17 Intermediate circuit of the external axes 16 X10/B Intermediate circuit of the robot axes, both con­17 X10/A
nections A/B parallel

Fuses On the KPS 600 there are 5 fuses to protect the DC 24 V and the batteries.

(>>> 11.7 "KPS 600 fuses, messages and error displays" page 112)

LEDs On the KPS 600 there are 6 LEDs which indicate the state of the safety logic

and the brake control. (>>> 11.7 "KPS 600 fuses, messages and error dis­plays" page 112)

2.7.2 Fuses

Overview The fuses protect the components of the robot controller.

Fig. 2-22: Arrangement of the fuses
1 F1-F3 Motor circuit-breaker 3 F19 Miniature circuit-breaker 2 F11-F14 Blowout fuses 4 F15, F16, FG3 Blowout fuses
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Values

Item Fuse Value in A Circuit
1 F1 20 KPS600 power supply
F2 7 KPS-27 power supply F3 0. 63 External fan power supply
2 F11 2 24 V DC voltage from KPS-27
F12 20 24 V DC voltage from KPS-27 F13 2 Lighting 24 V DC (optional)
F14 15 CI3 power supply 3 F19 2 Brakes for axes 1 to 6 4 F15 7.5 PC supply
F16 4 24 V DC supply for:
KCP CI3 RDC
FG3 10 Battery backup

2.7.3 Low-voltage power supply KPS-27

Description The KPS-27 is a 24 V power supply which provides power to the following

components:
Motor brake Periphery Control PC Servo drive module Batteries
Fig. 2-23: KPS-27 low-voltage power supply
1 Power supply connection 3 24 V DC output 2LED
LED One red and one green LED indicate the operating state of the KPS-27.
(>>> 11.8 "KPS-27 error messages" page 115)

2.7.4 KUKA Servo Drive (KSD)

Configuration The KSD incorporates:

Power output stage Current controller
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Interbus interface for the drive bus Monitoring of the motor current and short-circuit protection Heat sink temperature monitoring Communication monitoring
Fig. 2-24: Servo drive module
2. Product description

Sizes 2 sizes are used:

Size 1 (BG 1) KSD-08/16/32 Size 2 (BG 2) KSD-48/64
The designations 08 to 64 give the max. current in amps.

Connections

Fig. 2-25: Connections for servo drive modules, size 1 and size 2
1 X1 Connection 4 X2 Motor connection 2 X13 Interbus IN 5 X3 Additional motor connec-
tion
3 X14 Interbus OUT
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LED The LEDs on the servo drive modules indicate the operating status and any

2.7.5 Mains filter

Description The task of the mains filter (suppressor filter) consists of:

2.8 Cabinet cooling

Description The control cabinet is divided into two cooling circuits. The inner zone, con-

faults that may be present. (>>> 11.9 "Error messages on the KSD" page 115)
allowing 50 Hz / 60 Hz signals to pass through unimpeded suppressing conducted interference voltages
In the robot controller, the conducted interference voltages mainly emerge from the KPS600 and would spread throughout the entire power mains without mains filters.
taining the control electronics, is cooled by a heat exchanger. In the outer zone, the ballast resistor and the heat sinks of the servo modules and the KPS are cooled directly by ambient air.

Configuration

Caution!
Upstream installation of filter mats causes an excessive rise in temperature and hence a reduction in the service life of the installed devices!
Fig. 2-26: Outer cooling circuit
1 Air duct 5 Outer heat exchanger 2 Heat sink of the KSD 6 Mains filter 3 Heat sink of the KPS 7 Outer fan cooling circuit 4 Ballast resistors
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Fig. 2-27: Inner cooling circuit
2. Product description
1 Heat sink of the KSD 4 Inner heat exchanger 2 Fan for inner cooling circuit 5 Heat sink of the KPS 3Air duct

Optional cooling The robot controller can optionally be equipped with an additional cooling unit.

2.9 Description of interfaces

Overview The connection panel of the control cabinet consists as standard of connec-

tions for the following cables:
Power cable / infeed Motor cables to the robot Control cables to the robot KCP connection
The configuration of the connection panel varies according to the customer­specific version and the options required.
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Connection panel

Fig. 2-28: KR C2 ed05 connection panel
1 X1/XS1 power supply connec-
9 Optional
tion 2 X20 motor connection 10 X19 KCP connection 3 X7 motor connection 11 X21 RDC connection 4 Optional 12 PE1 ground conductor to the
robot
5 Optional 13 PE2 main infeed ground con-
ductor
6 Optional 14 X30 motor connection on the
robot base
7 X11 customer interface 15 X30.2 motor connection on the
robot base
8 Optional 16 X31 RDC connection on the
robot base
The motor connection X7 is used for:
Heavy-duty robots Robots with high payloads
All contactor, relay and valve coils that are connected to the robot controller by the user must be equipped with suitable suppressor diodes. RC elements and VCR resistors are not suitable.

2.9.1 Power supply connection X1/XS1

Description The robot controller can be connected to the mains via the following connec-

tions:
X1 Harting connector on the connection panel XS1 CEE connector; the cable is led out of the robot controller (optional)
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Overview

2. Product description
Caution!
If the robot controller is connected to a power system without a grounded neutral, this may cause malfunctions in the robot controller and material dam­age to the power supply units. The robot controller may only be operated with grounded-neutral power supply systems.
Fig. 2-29: Power supply connection
* The N-conductor is only necessary for the service socket option with a 400 V power supply.
The robot controller must only be connected to a power system with a clock­wise rotating field. Only then is the correct direction of rotation of the fan mo­tors ensured.
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2.9.2 KCP connector X19

Connector pin allocation

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2.9.3 Motor connector X20, axes 1 to 6

Connector pin allocation

2. Product description
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2.9.4 Motor connector X7 (optional)

Connector pin allocation

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2.9.5 Data cable X21, axes 1 to 8

Connector pin allocation

2. Product description

2.10 Description of the mounting plate for customer components (optional)

Overview The mounting plate for customer components is a mounting plate on the inside

of the door which can be fitted as an option for integrating external customer equipment.
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Fig. 2-30: Mounting plate for customer components
1 Drives (optional) 2 Mounting plate for customer components

Technical data

The drives project into the installation area of the mounting plate.
Designation Values
Weight of installed components max. 5 kg Power dissipation of installed components max. 20 W Depth of installed components 180 mm Width of mounting plate 400 mm Height of mounting plate 340 mm
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3 Technical data

3.1 Basic data

3. Technical data

Basic data

Power supply connection

Control cabinet type KR C2 edition05 Number of axes max. 8 Weight approx. 185 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-
1000 N
tribution
Standard rated supply voltage acc.
AC 3x400 V...AC 3x415 V
to DIN/IEC 38 Permissible tolerance of rated volt-
400 V -10%...415 V +10%
age Mains frequency 49...61 Hz Rated power input
Standard
Rated power input
Heavy-duty robot Palletizer Press-to-press robot
7.3 kVA, see rating plate
13.5 kVA, see rating plate
Mains-side fusing min. 3x25 A slow-blowing, max.
3x32 A slow-blowing, see rating plate
RCCB trip current difference 300 mA per robot controller, univer-
sal-current sensitive
Equipotential bonding The common neutral point for the
equipotential bonding conductors and all protective ground conduc­tors is the reference bus of the power unit.

Brake control

Environmental conditions

Output voltage 25-26 V DC Output current, brake max. 6 A Monitoring Open circuit and short circuit
Ambient temperature during opera-
+5 °C to 45 °C
tion without cooling unit Ambient temperature during opera-
+5 °C to 55 °C
tion with cooling unit Ambient temperature during stor-
-25°C to +30°C
age/transportation with batteries Ambient temperature during stor-
-25°C to +70°C
age/transportation without batteries Temperature change max. 1.1 K/min
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Vibration resistance

Control unit

Control PC

Humidity class acc. to EN 60204/
F
4.4.4 Altitude class according to DIN
N
40040
Type of loading
r.m.s. acceleration (sus-
During transportation
0.37 g 0.1 g
During continuous operation
tained oscillation) Frequency range (sustained
4 - 120 Hz 4 - 120 Hz
oscillation) Acceleration (shock in X/Y/Z
10 g 2.5 g
direction) Waveform/duration (shock
Half-sine/11 ms Half-sine/11 ms
in X/Y/Z direction)
If more severe mechanical stress is expected, the control cabinet must be fit­ted with anti-vibration mounts.
Supply voltage 26.8 V DC
Main processor See shipping version DIMM memory modules at least 256 MB Hard disk, floppy disk drive, CD-
See shipping version
ROM drive

KUKA Control Panel

Supply voltage 26.8 V DC Dimensions (WxHxD)
approx. 33x26x8 cm
3
VGA display resolution 640x480 pixels VGA display size 8" Weight 1.4 kg Cable length 10 m

Cable lengths The designations and standard and optional lengths may be noted from the

following table.
Cable Standard length in m Optional length in m
Motor cable 7 15 / 25 / 35 / 50 Data cable 7 15 / 25 /35 / 50 Power cable with XS1
2.9 -
(optional)
Cable Standard length in m Extension in m
KCP cable 10 10 / 20 / 30/ 40
When using KCP cable extensions only one may be employed at a time, and a total cable length of 60 m must not be exceeded.

3.2 KCP coupler (optional)

Basic data

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Power supply 24 V DC
Digital inputs 24 V DC pulsed, resistive load only Dimensions 147 mm x 73 mm

3.3 Dimensions of robot controller

3. Technical data
Fig. 3-1: Dimensions (in mm)
1 Cooling unit (optional) 3 Side view 2 Front view 4 Top view

3.4 Minimum clearances, robot controller

Fig. 3-2: Minimum clearances (dimensions in mm)
1 Cooling unit (optional)
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3.5 Minimum clearances, top-mounted / technology cabinet

Fig. 3-3: Minimum clearances with top-mounted / technology cabinet
1 Top-mounted cabinet 2 Technology cabinet

3.6 Swing range for cabinet door

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

3.7 Plates and labels

Overview The following plates and labels are attached to the control cabinet.

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3. Technical data
Fig. 3-4: Plates and labels
The plates may vary slightly from the examples illustrated depending on the specific cabinet type or as a result of updates.
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Designations

Plate no. Designation
1 Hot surface warning sign 2 Hand injury warning sign 3 Discharging time warning 4 KR C2 ed05 rating plate 5 Reference to operating instructions 6 PC rating plate 7 Start-up warnings on the door
Grounded neutral Check for tight fit of screws and terminals White cables Supply voltage warning
8 Fuse ratings 9 Power plug warning
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4 Safety

4.1 System planning

4.1.1 EC declaration of conformity and declaration of incorporation

4. Safety

EC declaration of conformity

The system integrator must issue a declaration of conformity for the overall system in accordance with Directive 98/37/EC (Machinery Directive). The dec­laration of conformity forms the basis for the CE mark for the system. The ro­bot system must be operated in accordance with the applicable national laws, regulations and standards.
The robot controller has a CE mark in accordance with Directive 89/336/EEC (EMC Directive) and Directive 73/23/EEC (Low Voltage Directive).
Declaration of incor­poration
A declaration of incorporation is provided for the robot system. This declara­tion of incorporation contains the stipulation that the robot system must not be commissioned until it complies with the provisions of 98/37/EC (Machinery Di­rective).

4.1.2 Installation site

Robot When planning the system, it must be ensured that the installation site (floor,

wall, ceiling) has the required grade of concrete and load-bearing capacity. The principal loads acting on the mounting base are indicated in the specifica­tions.
Further information is contained in the robot operating instructions.

Robot controller It is imperative to comply with the minimum clearances of the robot controller

from walls, cabinets and other system components.
Further information is contained in the robot controller operating instructions.

4.1.3 External safeguards

EMERGENCY STOP Additional Emergency Stop devices can be connected via interface X11 or

linked together by means of higher-level controllers (e.g. PLC).
The input/output signals and any necessary external power supplies must en­sure a safe state in the case of an Emergency Stop.
Further information is contained in the robot controller operating instructions.

Safety fences Requirements on safety fences are:

Safety fences must withstand all forces that are likely to occur in the
course of operation, whether from inside or outside the enclosure.
Safety fences must not, themselves, constitute a hazard. It is imperative to comply with the minimum clearances from the danger
zone.
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Safety gates Requirements on safety gates are:

Further information is contained in the corresponding standards and regula­tions.
The number of safety gates in the fencing must be kept to a minimum. All safety gates must be safeguarded by means of an operator safety sys-
tem (interface X11).
Automatic mode must be prevented until all safety gates are closed. In Automatic mode, the safety gate can be mechanically locked by means
of a safety system.
If the safety gate is opened in Automatic mode, it must trigger an Emer-
gency Stop function.
If the safety gate is closed, the robot cannot be started immediately in Au-
tomatic mode. The message on the control panel must be acknowledged.
Further information is contained in the corresponding standards and regula­tions.

Other safety equipment

Other safety equipment must be integrated into the system in accordance with the corresponding standards and regulations.

4.1.4 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards.
The danger zone consists of the workspace and the braking distances of the robot. It must be safeguarded by means of protective barriers to prevent dan­ger to persons or the risk of material damage.
Fig. 4-1: Example of axis range A1
1 Workspace 4 Safety zone
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2 Robot 5 Braking distance 3 Braking distance

4.2 Description

4.2.1 Category of the safety-oriented circuits

The following circuits correspond to Category 3 in accordance with EN 954-1:
EMERGENCY STOP systems Enabling switches Operator safety Operating modes Qualifying inputs

4.2.2 Stop reactions

Stop reactions of the robot system are triggered in response to operator ac­tions or as a reaction to monitoring functions and error messages. The follow­ing table shows the different stop reactions according to the operating mode that has been set.
4. Safety
STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204.
Trigger T1, T2 AUT, AUT EXT
EMERGENCY STOP pressed
Path-oriented braking
(STOP 0)
Path-maintaining brak-
ing
(STOP 1)
Start key released Ramp-down braking
-
(STOP 2)
Enabling switch released
Path-oriented braking
(STOP 0)
-
Safety gate opened - Path-maintaining brak-
ing
(STOP 1)
"Drives OFF" key pressed
Change operating mode
Encoder error (DSE-RDC connec-
Path-oriented braking
(STOP 0)
Path-oriented braking
(STOP 0)
Short-circuit braking
(STOP 0)
tion broken) Motion enable can-
celed
Ramp-down braking
(STOP 2)
STOP key pressed Ramp-down braking
(STOP 2)
Robot controller switched off
Short-circuit braking
(STOP 0)
Power failure
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Stop reaction Drives Brakes Software
Ramp-down braking (STOP 2)
Path-main­taining brak­ing (STOP 1)
Drives remain on.
Drives are switched off after 1 second hardware
Brakes remain open.
Brakes are applied after 1 s at latest.
Normal ramp which is used for acceleration and deceleration.
In this time the control­ler brakes the robot on the path using a steep­er stop ramp.
delay.
Path-oriented braking (STOP 0)
Drives are switched off immediately.
Brakes are applied imme­diately.
The controller attempts to brake the robot on the path with the re­maining energy. If the voltage is not suffi­cient, the robot leaves the programmed path.
Short-circuit braking (STOP 0)
Drives are switched off immediately.
Brakes are applied imme­diately.
-

4.2.3 Labeling on the robot system

All plates, labels, symbols and marks constitute safety-relevant parts of the ro­bot system. They must not be modified or removed.
Labeling on the robot system consists of:
Rating plates Warning labels Safety symbols Designation labels Cable markings Identification plates

4.2.4 Safety information

Safety information cannot be held against the KUKA Robot Group. Even if all safety instructions are followed, this is not a guarantee that the robot system will not cause personal injuries or material damage.
No modifications may be carried out to the robot system without the authori­zation of the KUKA Robot Group. Additional components (tools, software, etc.), not supplied by KUKA Robot Group, may be integrated into the robot system. The user is liable for any damage these components may cause to the robot system.
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4.3 Safety features

4.3.1 Overview of the safety features

The following table indicates the operating modes in which the safety features are active.
Safety features T1 T2 AUT AUT EXT Operator safety ­Emergency Stop button
(STOP 0) Emergency Stop button
(STOP 1) Enabling switch active Reduced velocity Jog mode Software limit switches active
4. Safety
- active active
active active - -
- - active active
active - -
active - - -
active active - -
active active active
Danger!
In the absence of functional safety equipment, the robot can cause personal injury or material damage. No safety equipment may be dismantled or deac­tivated while the robot is in operation.

4.3.2 ESC safety logic

The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer­aided safety system. It permanently monitors all connected safety-relevant components. In the event of a fault or interruption in the safety circuit, the pow­er supply to the drives is shut off, thus bringing the robot system to a standstill.
The ESC safety logic monitors the following inputs:
Local EMERGENCY STOP External EMERGENCY STOP Operator safety Enabling Drives OFF Drives ON Operating modes Qualifying inputs
Further information is contained in the robot controller operating instructions.

4.3.3 Operator safety input

The operator safety input is used for interlocking fixed guards. Safety equip­ment, such as safety gates, can be connected to the dual-channel input. If nothing is connected to this input, operation in Automatic mode is not possible. Operator safety is not active for test modes T1 and T2.
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4.3.4 EMERGENCY STOP button

In the event of a loss of signal during Automatic operation (e.g. safety gate is opened), the drives are deactivated after 1 s and the robot stops with a STOP
1. Once the signal is active at the input again (e.g. safety gate closed and sig­nal acknowledged), Automatic operation can be resumed.
Operator safety can be connected via interface X11.
Further information is contained in the robot controller operating instructions.
The EMERGENCY STOP button for the robot system is located on the KCP. If the EMERGENCY STOP button is pressed, the drives are deactivated im­mediately in operating modes T1 and T2 and the robot stops with a STOP 0. In the Automatic operating modes, the drives are deactivated after 1 s and the robot stops with a STOP 1. The EMERGENCY STOP button must be pressed as soon as persons or equipment are endangered. Before operation can be resumed, the EMERGENCY STOP button must be turned to release it and the error message must be acknowledged.
Fig. 4-2: EMERGENCY STOP button on the KCP
1 EMERGENCY STOP button

4.3.5 Enabling switches

There are 3 enabling switches installed on the KCP. These 3-position enabling switches can be used to switch on the drives in modes T1 and T2.
In the test modes, the robot can only be moved if one of the enabling switches is held in the central position. If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the robot stops with a STOP 0.
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4. Safety
Fig. 4-3: Enabling switches on the KCP
1 - 3 Enabling switches

4.3.6 Jog mode

In modes T1 and T2, the robot can only be moved in jog mode. For this, an enabling switch and the Start key must be kept held down. If the enabling switch is released or pressed fully down (panic position), the drives are deac­tivated immediately and the robot stops with a STOP 0. Releasing the Start key causes the robot to be stopped with a STOP 2.

4.3.7 Mechanical end stops

The axis ranges of main axes A 1 to A 3 and wrist axis A 5 are limited by means of mechanical limit stops with a buffer.
Danger!
If the robot hits an obstruction or a buffer on the mechanical end stop or axis range limitation, this can result in material damage to the robot. The KUKA Robot Group must be consulted before the robot is put back into operation (>>> 13 "KUKA Service" page 147). The affected buffer must immediately be replaced with a new one. If a robot collides with a buffer at more than 250 mm/s, the robot must be exchanged or recommissioning must be carried out by the KUKA Robot Group.

4.3.8 Mechanical axis range limitation (option)

Most robots can be fitted with mechanical axis range limitation in main 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.
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4.3.9 Axis range monitoring (option)

This option can be retrofitted.
Further information is contained in the working range limitation operating in­structions.
Most robots can be fitted with dual-channel axis range monitoring systems in main axes A1 to A3. The safety zone for an axis can be adjusted and moni­tored using an axis range monitoring system. This increases personal safety and protection of the system.
This option can be retrofitted.
Further information is contained in the working range monitoring operating in­structions.

4.3.10 Software limit switches

The axis ranges of all robot 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 robot cannot hit the mechanical limit stops.
Further information is contained in the operating and programming instruc­tions.

4.3.11 Release device (option)

Description The release device can be used to move the robot mechanically after an acci-

dent 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 mo­tors. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people). After use of the release device, the affected motors must be exchanged.
Caution!
The motors reach temperatures during operation which can cause burns to the skin. Appropriate safety precautions must be taken.

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.
4. Exchange the motor.
5. Remaster all robot axes.
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4.3.12 KUKA.SafeRobot (option)

KUKA.SafeRobot is an option with software and hardware components.
This option may only be retrofitted after consultation with the KUKA Robot Group.
4. Safety

Properties

Connection to an external safety logic Monitoring that can be activated using safe inputs Freely definable axis-specific monitoring Safe monitoring of axis-specific and Cartesian velocities and accelerations Safe standstill monitoring Safe stop via Electronic Safety Circuit (ESC) with safe disconnection of the
drives
Monitoring of the mastering Brake test

Functional principle The robot moves within the limits that have been configured and activated.

The actual position is continuously calculated and monitored against the safe­ty parameters that have been set.
The SafeRDC monitors the robot system by means of the safety parameters that have been set. If the robot violates a monitoring limit or a safety parame­ter, it is stopped.
The safe inputs and outputs of the SafeRDC are of a redundant design and LOW active.
Further information is contained in the KUKA System Technology KU-
KA.SafeRobot documentation.

4.4 Personnel

User The user of a robot system is responsible for its use. The user must ensure

that it can be operated in complete safety and define all safety measures for personnel.

System integrator The robot system is safely integrated into a plant by the system integrator.

The system integrator is responsible for the following tasks:
Installing the robot system Connecting the robot system Implementing the required facilities Issuing the declaration of conformity Attaching the CE mark

Operator The operator must meet the following preconditions:

The operator must have read and understood the robot system documen-
tation, including the safety chapter.
The operator must be trained for the work to be carried out. Work on the robot system must only be carried out by qualified personnel.
These are people who, due to their specialist training, knowledge and ex­perience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential dangers.
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Example The tasks can be distributed as shown in the following table.

Tasks Operator Programmer
Switch robot
xx x
controller on/off Start program Select program Select operating
xx x
xx x
xx x
mode Calibration
xx
(tool, base) Master the robot Configuration Programming
xx
xx
xx
Start-up Maintenance Repair Shut-down Transportation
Maintenance technician
x
x
x
x
x
Work on the electrical and mechanical equipment of the robot system may only be carried out by specially trained personnel.

4.5 Safety measures

4.5.1 General safety measures

The robot system may only be used in perfect technical condition in accord­ance with its designated 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 robot even after the robot controller has been switched off and locked. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the robot to sag. If work is to be carried out on a switched-off robot, the robot must first be moved into a position in which it is unable to move on its own, whether the payload is mounted or not. If this is not possible, the robot must be secured by appropriate means.
KCP The KCP must be removed from the system if it is not connected, as the
EMERGENCY STOP button is not functional in such a case.
If there are several KCPs in a system, it must be ensured that they are not mixed up.
No mouse or keyboard may be connected to the robot controller.

Faults The following tasks must be carried out in the case of faults to the robot sys-

tem:
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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. Keep a record of the faults. Eliminate the fault and carry out a function test.

4.5.2 Transportation

Robot The prescribed transport position of the robot must be observed. Transporta-

tion must be carried out in accordance with the robot operating instructions.
Further information is contained in the robot operating instructions.

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.
Further information is contained in the robot controller operating instructions.
4. Safety

4.5.3 Start-up

The robot controller must not be put into operation until the internal tempera­ture of the cabinet has adjusted to the ambient temperature. Otherwise, con­densation could cause damage to electrical components.

Function test It must be ensured that no persons or objects are present within the danger

zone of the robot during the function test.
The following must be checked during the function test:
The robot system is installed and connected. There are no foreign bodies
or destroyed, loose parts on the robot or in the robot controller.
All safety devices and protective measures are complete and fully func-
tional.
All electrical connections are correct. The peripheral devices are correctly connected. The external environment corresponds to the permissible values indicated
in the operating instructions.
Further information is contained in the robot operating instructions and in the robot controller operating instructions.

Setting It must be ensured that the ratings plate on the robot controller has the same

machine data as those entered in the declaration of incorporation. The ma­chine data on the ratings plate of the robot must be entered during start-up.
The robot must not be moved unless the correct machine data are not loaded. Otherwise, damage to property could occur.
Further information is contained in the operating and programming instruc­tions.
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4.5.4 Programming

The following safety measures must be carried out during programming:
It must be ensured that no persons are present within the danger zone of
the robot during programming.
New or modified programs must always be tested first in operating mode
T1.
If the drives are not required, they must be switched off to prevent the robot
from being moved unintentionally.
The motors reach temperatures during operation which can cause burns
to the skin. Contact should be avoided if at all possible. If necessary, ap­propriate protective equipment must be used.
The robot and its tooling must never touch or project beyond the safety
fence.
Components, tooling and other objects must not become jammed as a re-
sult of the robot motion, nor must they lead to short-circuits or be liable to fall off.
The following safety measures must be carried out if programming in the dan­ger zone of the robot:
The robot must only be moved at reduced velocity (max. 250 mm/s). In this
To prevent other persons from being able to move the robot, the KCP must
If two or more persons are working in the system at the same time, they

4.5.5 Automatic mode

Automatic mode is only permissible in compliance with the following safety measures.
The prescribed safety equipment is present and operational. There are no persons in the system. The defined working procedures are adhered to.
If the robot comes to a standstill for no apparent reason, the danger zone must not be entered until the EMERGENCY STOP function has been triggered.
way, persons have enough time to move out of the way of hazardous robot motions or to stop the robot.
be kept within reach of the programmer.
must all use an enabling switch. While the robot is being moved, all per­sons must remain in constant visual contact and have an unrestricted view of the robot system.
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5Planning

5.1 Overview of planning

This is an overview of the most important planning specifications. The pre­cise planning depends on the application, the robot type, the technology packages used and other customer-specific circumstances.
For this reason, the overview does not claim to be comprehensive.

Robot controller

Step Description Information
1 Electromagnetic compatibility (EMC) (>>> 5.2 "Electromagnetic compat-
ibility (EMC)" page 65)
2 Installation conditions for robot controller (>>> 5.3 "Installation conditions"
page 66)
3 Connection conditions (>>> 5.4 "Connection conditions"
page 67)
4 Power supply connection (>>> 5.5 "Power supply connec-
tion" page 68)
5 E-STOP circuit and safeguard (>>> 5.6 "EMERGENCY STOP cir-
cuit and safeguard" page 70) 6 Configuration of interface X11 (>>> 5.7 "Interface X11" page 71) 7 Equipotential bonding (>>> 5.8 "PE equipotential bond-
ing" page 74) 8 KCP coupler (optional) (>>> 5.9 "Planning the KCP cou-
pler option" page 75)
5. Planning

5.2 Electromagnetic compatibility (EMC)

Description If connecting cables (e.g. DeviceNet, 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).
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5.3 Installation conditions

Dimensions

Minimum clearances

Fig. 5-1: Dimensions (in mm)
1 Cooling unit (optional) 3 Side view 2 Front view 4 Top view
Fig. 5-2: Minimum clearances (dimensions in mm)
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Minimum clear­ances with top­mounted cabinet
5. Planning

Swing range for door

Fig. 5-3: Minimum clearances with top-mounted / technology cabinet
1 Top-mounted cabinet 2 Technology cabinet
Swing range, standalone cabinet:
Door with computer frame approx. 180°
Swing range, butt-mounted cabinets:
Door approx. 155°

5.4 Connection conditions

Power supply connection

Standard rated supply voltage acc. to DIN/IEC 38
Permissible tolerance of rated volt­age
Mains frequency 49...61 Hz
AC 3x400 V...AC 3x415 V
400 V -10%...415 V +10%
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Rated power input
Standard
Rated power input
Heavy-duty robot Palletizer Press-to-press robot
7.3 kVA, see rating plate
13.5 kVA, see rating plate
Mains-side fusing min. 3x25 A slow-blowing, max.
3x32 A slow-blowing, see rating
plate
RCCB trip current difference 300 mA per robot controller, univer-
sal-current sensitive
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit.
Caution!
If the robot controller is connected to a power system without a grounded neutral, this may cause malfunctions in the robot controller and material dam­age to the power supply units. The robot controller may only be operated with grounded-neutral power supply systems.

Cable lengths The designations and standard and optional lengths may be noted from the

following table.
Cable Standard length in m Optional length in m
Motor cable 7 15 / 25 / 35 / 50 Data cable 7 15 / 25 /35 / 50 Power cable with XS1
2.9 -
(optional)
Cable Standard length in m Extension in m
KCP cable 10 10 / 20 / 30/ 40
When using KCP cable extensions only one may be employed at a time, and a total cable length of 60 m must not be exceeded.

5.5 Power supply connection

Description The robot controller can be connected to the mains via the following connec-

tions:
X1 Harting connector on the connection panel XS1 CEE connector; the cable is led out of the robot controller (optional)
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Overview

Fig. 5-4: Power supply connection
* The N-conductor is only necessary for the service socket option with a 400 V power supply.
The robot controller must only be connected to a power system with a clock­wise rotating field. Only then is the correct direction of rotation of the fan mo­tors ensured.

5.5.1 Power supply connection via X1 Harting connector

5. Planning

Description A Harting connector bypack (1) is supplied with the robot controller. The cus-

tomer can use this to establish a connection between X1 (2) on the robot con­troller and the power supply.
Fig. 5-5: Power supply connection X1

5.5.2 Power supply connection via CEE connector XS1

Description With this option, the robot controller is connected to the power supply via a

CEE connector (2). The cable is approx. 2.9 m long and is routed to the main switch via a cable gland (1).
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5.6 EMERGENCY STOP circuit and safeguard

Fig. 5-6: Power supply connection XS1
The following examples show how the EMERGENCY STOP circuit and safe­guard of the robot system can be connected to the periphery.

Example

Fig. 5-7: Robot with periphery
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Example

5. Planning
Fig. 5-8: Robot with periphery and external power supply

5.7 Interface X11

Description EMERGENCY STOP devices must be connected via interface X11 or linked

together by means of higher-level controllers (e.g. PLC).

Wiring Take the following points into consideration when wiring interface X11:

System concept Safety concept
Various signals and functions are available, depending on the specific CI3 board. (>>> 2.6.2 "Overview of CI3 boards" page 25)
Detailed information about integration into higher-level controllers is con­tained in the Operating and Programming Instructions for System Integra­tors, in the chapter “Automatic External signal diagrams”.
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Connector pin allocation

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Signal Pin Description Comments
+24 V internal
106
ESC power supply max. 2 A
5. Planning
0 V internal 24 V external
0 V external
+24 V
0V +24 V
0V Test output A
(test signal)
Test output B
(test signal)
Local E-STOP channel A
Local E-STOP channel B
External E-STOP channel A
External E-STOP channel B
Enabling chan­nel A
Enabling chan­nel B
Safeguard chan­nel A
Safeguard chan­nel B
Drives OFF external, channel A (single-chan­nel)
Drives ON exter­nal, channel B (single-channel)
Drives ON chan­nel B
107 88
89
36
18 90
72 1
5
In the absence of an external power supply, 24 V / 0 V must be jumpered internally.
24 V control voltage for supply to external devices, max. 4 A.
24 V control voltage for supply to external devices, max. 6 A.
Makes the pulsed voltage avail­able for the individual interface inputs of channel A.
7
38
41 19
23
Makes the pulsed voltage avail­able for the individual interface inputs of channel B.
25
39
43 20 / 21 Output, floating contacts from
internal E-STOP, max. 24 V,
2 / 3
600 mA
4 E-STOP, dual-channel input,
max. 24 V, 10 mA.
22
6 For connection of an external
dual-channel enabling switch
24
with floating contacts max. 24 V, 10 mA
8 For dual-channel connection of
a safety gate locking mecha-
26
nism, max. 24 V, 10 mA
42 A floating contact (break con-
tact) can be connected to this input. If the contact opens, the drives are switched off, max. 24 V, 10 mA.
44 For connection of a floating
contact.
29 / 30 Floating contacts (max. 7.5 A)
signal “Drives ON”.
An external power supply is recommended for interlinked systems.
Optional
Optional
Connection example: enabling switch is connected under channel A to pin 1 (TA_A) and pin 6.
Connection example: safety gate locking mechanism is con­nected under channel B to pin 19 (TA_B) and pin 26.
In the non-activated state, the contacts are closed.
If no enabling switch is con­nected, pins 5 and 6 and pins 23 and 24 must be jumpered. Only effective in TEST mode.
Only effective in AUTOMATIC mode.
If this input is not used, pins 41/ 42 must be jumpered.
Pulse > 200 ms switches the drives on. Signal must not be permanently active.
Is closed if the “Drives ON” contactor is energized.
These contacts are only availa­ble if a CI3 Extended or CI3 Tech board is used.
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Signal Pin Description Comments
Drives ON chan­nel A
Operating mode group Automatic
Operating mode group Test
Qualifying input, channel A
Qualifying input, channel B
11 / 12 Floating contacts (max. 2 A)
signal “Drives ON”.
Is closed if the “Drives ON” contactor is energized.
These contacts are only availa­ble if a CI3 Extended or CI3 Tech board is used.
48 / 46 Floating contacts of the safety
circuit signal the operating mode.
48 / 47 Test contact 48 / 47 is closed if
These contacts are only availa­ble if a CI3 Extended or CI3 Tech board is used.
50 0 signal causes a category 0
STOP in all operating modes.
51
Automatic contact 48 / 46 is closed if Automatic or External is selected on the KCP.
Test 1 or Test 2 is selected on the KCP.
If these inputs are not used, pin 50 must be jumpered to test output 38, and pin 51 to test output 39.
The counterpart to interface X11 is a 108-contact Harting connector with a male insert, type Han 108DD, housing size 24B.

I/Os I/Os can be configured using the following components:

DeviceNet (master) via MFC Optional field bus cards
Interbus Profibus
DeviceNet
ProfiNet Specific customer interfaces

5.8 PE equipotential bonding

Description

A 16 mm the robot controller.
2
cable must be used as equipotential bonding between the robot and
Fig. 5-9: Equipotential bonding, from controller to robot , with cable duct
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5. Planning
1 Equipotential bonding to KR C2
4 Cable duct
ed05
2 Equipotential bonding from the
connection panel to the cable
5 Equipotential bonding from the
cable duct to the robot
duct
3 Connection panel, KR C2 ed05 6 Equipotential bonding connec-
tion on the robot
Fig. 5-10: Equipotential bonding, from controller to robot
1 Equipotential bonding to KR C2
ed05
3 Equipotential bonding from the
connection panel to the robot
2 Connection panel, KR C2 ed05 4 Equipotential bonding connec-
tion on the robot

5.9 Planning the KCP coupler option

Visualization If the robot controller is operated with a detachable KCP, the following system

variables must be visualized:
$Mode_T1 (T1 mode) $Mode_T2 (T2 mode) $Mode_Ext (External mode) $Mode_Aut (Automatic mode) $Notaus (Emergency Stop) $Pro_Act (program active)
The display can be configured using I/Os or a PLC. The system variables can be configured in the file: STEU/$MACHINE.DAT.
Warning!
If the KCP is disconnected, the system can no longer be deactivated by means of the E-STOP button on the KCP. An external E-STOP must be con­nected to interface X11 to prevent personal injury and material damage.
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6 Transportation

6.1 Transportation using lifting tackle

Preconditions The control cabinet must be switched off.

No cables may be connected to the control cabinet. The door of the control cabinet must be closed. The control cabinet must be upright. The anti-toppling bracket must be fastened to the control cabinet.
6. Transportation
Necessary
Lifting tackle with or without lifting frame
equipment

Procedure 1. Attach the lifting tackle with or without a lifting frame to all 4 transport eye-

bolts on the control cabinet.
Fig. 6-1: Transportation using lifting tackle
1 Transport eyebolts on the control cabinet 2 Correctly attached lifting tackle 3 Correctly attached lifting tackle 4 Incorrectly attached lifting tackle
2. Attach the lifting tackle to the crane.
Danger!
If the suspended control cabinet is transported too quickly, it may swing and cause injury or damage. Transport the control cabinet slowly.
3. Slowly lift and transport the control cabinet.
4. Slowly lower the control cabinet at its destination.
5. Detach the lifting tackle from the control cabinet.
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6.2 Transportation by pallet truck

Preconditions The control cabinet must be switched off.

Procedure

No cables may be connected to the control cabinet. The door of the control cabinet must be closed. The control cabinet must be upright. The anti-toppling bracket must be fastened to the control cabinet.
Fig. 6-2: Transportation by pallet truck
1 Control cabinet with anti-toppling bracket 2 Control cabinet in raised position

6.3 Transportation by fork lift truck

Preconditions The control cabinet must be switched off.

No cables may be connected to the control cabinet. The door of the control cabinet must be closed. The control cabinet must be upright. The anti-toppling bracket must be fastened to the control cabinet.

Procedure

Fig. 6-3: Transportation by fork lift truck
1 Control cabinet with fork slots 2 Control cabinet with transformer installation kit
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7 Start-up

7.1 Start-up overview

This is an overview of the most important steps during start-up. The precise sequence depends on the application, the robot type, the technology pack­ages used and other customer-specific circumstances. This overview refers to the start-up of the robot system. The start-up of the overall system is not within the scope of this documentation.
For this reason, the overview does not claim to be comprehensive.

Robot

Step Description Information
1 Carry out a visual inspection of the robot. Detailed information is contained in 2 Install the robot mounting base (mounting base,
machine frame mounting or booster frame).
3 Install the robot.
the robot operating instructions, in the chapter “Start-up”.
7. Start-up

Electrical system

Step Description Information
4 Carry out a visual inspection of the robot control-
ler.
5 Make sure that no condensation has formed in
the robot controller.
6 Install the robot controller. (>>> 7.2 "Installing the robot con-
troller" page 80)
7 Connect the connecting cables. (>>> 7.3 "Connecting the connect-
ing cables" page 80)
8 Connect the KCP. (>>> 7.4 "Connecting the KCP"
page 81)
9 Establish the equipotential bonding between the
robot and the robot controller.
10 Connect the robot controller to the power supply. (>>> 2.9.1 "Power supply connec-
11 Reverse the battery discharge protection meas-
ures.
12 Configure and connect interface X11.
Note: If interface X11 has not been wired, the robot cannot be jogged.
13 Switch the robot controller on. (>>> 7.10 "Switching on the robot
14 Check the direction of rotation of the fans. (>>> 7.11 "Checking the direction
15 Check the safety equipment. Detailed information is contained in
16 Configure the inputs/outputs between the robot
controller and the periphery.
(>>> 7.5 "Connecting the PE equi­potential bonding" page 81)
tion X1/XS1" page 40) (>>> 7.7 "Reversing the battery
discharge protection measures" page 82)
(>>> 5.7 "Interface X11" page 71)
controller" page 82)
of rotation of the external fan" page 83)
the robot operating instructions, in the chapter “Safety”.
Detailed information can be found in the field bus documentation.
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Software

Step Description Information
17 Check machine data. Detailed information is contained in 18 Master the robot without a load. 19 Mount the tool and master the robot with a load.
the operating and programming instructions.
20 Check the software limit switches and adapt
them if required.
21 Calibrate the tool.
In the case of a fixed tool: calibrate external TCP. 22 Enter load data. 23 Calibrate base (optional).
In the case of a fixed tool: calibrate workpiece
(optional). 24 If the robot is to be controlled from a host com-
puter or PLC: configure Automatic External inter-
face.
Detailed information is contained in the Operating and Programming Instructions for System Integrators.
Long text names of inputs/outputs, flags, etc., can be saved in a text file and imported after a reinstallation. In this way, the long texts do not need to be re-entered manually for each robot. Furthermore, the long text names can be updated in application programs.

Accessories Precondition: the robot is ready to move, i.e. the software start-up has been

carried out up to and including the item “Master robot without load”.
Description Information
Optional: install axis range limitation systems. Adapt software limit switches.
Detailed information can be found in the axis range limitation docu­mentation.
Optional: install and adjust axis range monitoring, taking the programming into consideration.
Detailed information can be found in the axis range monitoring docu­mentation.
Optional: install and adjust external energy supply system, taking the programming into consideration.
Detailed information can be found in the energy supply system docu­mentation.
Positionally accurate robot option: check data.

7.2 Installing the robot controller

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

nets, etc. must be observed. (>>> 5.3 "Installation conditions" page 66)
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.

7.3 Connecting the connecting cables

Overview A cable set is supplied with the robot system. In the standard version this con-

sists of:
Motor cable to the robot
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Control cable to the robot
The following cables may be provided for additional applications:
Motor cable for external axes Peripheral cables
Danger!
The robot controller is preconfigured for specific robots. If cables are inter­changed, the robot may receive incorrect data and can thus cause personal injury or material damage. If a system consists of more than one robot, al­ways connect the connecting cables to the robots and their corresponding ro­bot controllers.

Procedure 1. Route the motor cable to the robot junction box separately from the control

cable. Plug in connector X20.
2. Route the control cable to the robot junction box separately from the motor cable. Plug in connector X21.
3. Connect the peripheral cables.
7. Start-up
Fig. 7-1: Example: Installing the cables in the cable duct
1 Cable duct 4 Motor cables 2 Separating webs 5 Control cables 3 Welding cables

7.4 Connecting the KCP

Procedure Connect the KCP to X19 on the robot controller.

7.5 Connecting the PE equipotential bonding

Procedure

1. Route and connect a 16 mm robot and the robot controller. (>>> 5.8 "PE equipotential bonding" page 74)
2. Carry out a ground conductor check for the entire robot system in accord­ance with DIN EN 60204-1.
2
cable as equipotential bonding between the

7.6 Connecting the robot controller to the power supply

Procedure Connect the robot controller to the power supply via X1 or XS1.

(>>> 5.5.1 "Power supply connection via X1 Harting connector" page 69) (>>> 5.5.2 "Power supply connection via CEE connector XS1" page 69)
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7.7 Reversing the battery discharge protection measures

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 X7 dis­connected from the KPS600.

Procedure

Plug connector X7 (1) into the KPS600.
Fig. 7-2: Reversing the battery discharge protection measures

7.8 Connecting the EMERGENCY STOP circuit and safeguard

Procedure 1. Connect the EMERGENCY STOP circuit and safeguard (operator safety)

to interface X11. (>>> 5.6 "EMERGENCY STOP circuit and safeguard" page 70)

7.9 Configuring and connecting connector X11

Procedure 1. Configure connector X11 in accordance with the system and safety con-

cepts.
2. Connect interface connector X11 to the robot controller.

7.10 Switching on the robot controller

Precondition The door of the control cabinet is closed.

All electrical connections are correct and the energy levels are within the
specified limits.
It must be ensured that no persons or objects are present within the dan-
ger zone of the robot.
All safety devices and protective measures are complete and fully func-
tional.
The internal temperature of the cabinet must have adapted to the ambient
temperature.

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

2. Unlock the EMERGENCY STOP button on the KCP.
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3. Switch on the main switch. The control PC begins to run up the operating system and the control software.
Information about operator control of the robot using the KCP can be found in the operating and programming instructions for the KUKA System Soft­ware (KSS).

7.11 Checking the direction of rotation of the external fan

Procedure Check outlet (2) on the rear of the robot controller.

7. Start-up
Fig. 7-3: Checking the direction of rotation of the fan
1 Air inlet 2 Air outlet
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8 Operation

8.1 Display and operator control elements of the KCP coupler (optional)

Overview

8. Operation
Fig. 8-1: KCP coupler LEDs and request button
1 Fault LED (red), KCP coupler 2 Request button with request LED (green)

8.1.1 Uncoupling the KCP

Procedure 1. Press the request button for at least 1 s.

The green request LED flashes. The KCP is switched off (display goes dark).
Caution!
The KCP must not be disconnected without pressing the request button. If the KCP is disconnected without the request button being pressed, an EMERGENCY STOP is triggered.
2. Disconnect the KCP within 60 s.
Caution!
The KCP with EMERGENCY STOP is deactivated for the request time of 60 s. The EMERGENCY STOP on the KCP is not activated during this time.
3. The KCP must be removed from the system.
Caution!
The KCP must be removed from the system if it is not connected. The EMER­GENCY STOP is not operational in this case.

8.1.2 Coupling the KCP

Preconditions The KCP variant to be coupled must be the same as that which was un-

coupled.
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Procedure 1. Set the operating mode on the KCP to the same operating mode as on the

8.2 Booting the robot controller from a USB stick

Precondition Robot controller is switched off.

Procedure 1. Plug in bootable USB stick.

robot controller (the operating mode display is application-specific (>>> 5.9 "Planning the KCP coupler option" page 75)).
If the KCP is connected with the wrong operating mode selected, the robot controller switches to the operating mode set on the KCP.
2. Couple the KCP to the robot controller. The request LED flashes quickly. Once coupling has been completed, the request LED lights up and the
KCP display shows the user interface. The robot controller can once again be operated via the KCP.
External keyboard.
2. Switch on the robot controller.
3. Press F10 during the boot procedure.
Caution!
If a KCP and an external keyboard are connected to the robot controller, 2 people can operate the robot system simultaneously. This can result in per­sonal injury and material damage. Take measures to secure the robot sys­tem against unauthorized operation and remove the external keyboard from the system immediately completion of the installation process.
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9 Maintenance

9.1 Maintenance table

9. Maintenance

Maintenance table

Fig. 9-1: Maintenance points
Item Activity Time re-
quired [min]
1 Clean fan for inner
cooling circuit with brush.
Clean fan for outer cooling circuit with brush.
2 Clean heat ex-
changer with brush.
Clean heat sink with brush and check that it is se­curely fastened.
1 Exchange fan for
inner cooling cir­cuit. (>>> 10.2 "Exchan ging the internal fan" page 90)
Exchange fan for outer cooling cir­cuit. (>>> 10.3 "Exchan ging the external fan" page 91)
Maintenance interval
15 Depends on installation
conditions and degree of fouling; however, no later
15
15
15
20 5 years (with 3-shift op-
20
than every 2 years
eration)
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Item Activity Time re-
quired [min]
3 Exchange the bat-
5 2 years teries. (>>> 10.10 "Excha nging the batteries" page 95)
4 Exchange the
20 5 years motherboard bat­tery. (>>> 10.7 "Exchan ging the mother­board battery" page 94)
5 Exchange the PC
2 5 years (with 3-shift op­fan. (>>> 10.6 "Exchan ging the PC fans" page 93)
6 Exchange the filter
1 Depends on installation insert. (>>> 10.4 "Exchan ging the pressure relief plug" page 91)
Maintenance interval
eration)
conditions and degree of
fouling. Visual check:
change filter insert if dis-
colored (original color:
white).
Once an activity from the maintenance list has been carried out, a visual in­spection must be made, with special attention to the following points:
Secure fit of fuses, contactors, plug-in connections and boards. PE equipotential bonding connection. Damage to cabling.

9.2 Cleaning the robot controller

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Work regulations

Procedure 1. Loosen and vacuum up any dust deposits.

The manufacturer’s instructions must be observed when carrying out
cleaning work.
It must be ensured that no cleaning fluid enters electrical components. Do not use compressed air during cleaning work.
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.
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10 Repair

10.1 Service jumper plug X11

The service jumper plug X11 is a Harting connector with a male insert, type Han 108DD, housing size 24B.

Connector pin allocation

10. Repair
Caution!
The jumper plug is only to be used during start-up and troubleshooting. If the jumper plug is used, the connected safety components are disabled.
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10.2 Exchanging the internal fan

Preconditions The robot controller must be switched off and secured to prevent unau-

Procedure 1. Open the control cabinet door.

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.
2. Remove the domed cap nuts and the lock nuts underneath them from the fan plate.
3. Tilt the fan plate downwards together with the fan.
4. Unplug the fan connector.
Fig. 10-1: Exchanging the internal fan
1 Domed cap nuts and lock
2 Fan connector
nuts
5. Pull the fan plate forwards to remove it.
6. Note the fan installation position (direction of rotation).
7. Unscrew the fan from the mounting.
8. Screw on the new fan. Observe correct installation position (direction of ro­tation).
9. Insert the tab end of the fan plate into the slot.
3 Fan fastening screws 4 Tab end
10. Plug in the fan connector.
11. Swing the fan plate up into place and fasten it with new lock nuts.
12. Screw on the domed cap nuts.
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10.3 Exchanging the external fan

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Remove the transport safeguard and slacken the fastening screws on the

rear panel.
2. Take off the rear panel.
3. Unscrew the screws of the cable inlet.
4. Unplug the fan connector.
5. Remove the screws from the fan holder.
6. Take off the fan with the holder.
7. Install the new fan.
8. Plug in the fan connector and fasten the cable.
9. Mount the rear cabinet panel and fasten.
10. Repair
Fig. 10-2: Exchanging the external fan
1 Fastening screws and trans-
4 Cable inlet
port safeguard 2 Holder with fan 5 Cable to fan connector 3 Fan holder fastening

10.4 Exchanging the pressure relief plug

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.
Back-up must be completed. The power cable must be de-energized.
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Procedure 1. Open the control cabinet door.

Observe the ESD guidelines.
2. Remove the foam ring.
3. Exchange the filter insert.
4. Insert the foam ring so that it is flush with the pressure relief plug.
Fig. 10-3: Exchanging the pressure relief plug
1 Pressure relief plug 3 Foam ring 2 Filter insert

10.5 Exchanging the PC

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the control cabinet door.

2. Unplug the power supply and all connections to the PC interface.
3. Remove the transport safeguard screw.
4. Slacken the knurled nuts.
5. Remove the PC and lift it out towards the top.
6. Insert the new PC and fasten.
7. Plug in the connections.
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Fig. 10-4: Removing and installing the control PC
10. Repair
1 Plug-in connections on the PC 3 Transport safeguard screw 2 Knurled nut

10.6 Exchanging the PC fans

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Remove the cable strap.

2. Unplug the fan connector.
3. Note the fan installation position (direction of rotation).
4. Remove the fan retaining screws.
5. Take off the fan with the fan grille.
6. Insert the new fan and fasten. Observe correct installation position (direc­tion of rotation).
7. Plug in the fan connector and secure the cables with cable straps.
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Fig. 10-5: Exchanging the PC fan
1 Fan connector 3 Fan fastening screws 2 Cable strap

10.7 Exchanging the motherboard battery

The battery on the motherboard of the control PC may only be exchanged by authorized maintenance personnel in consultation with the KUKA customer support service.

10.8 Exchanging the motherboard

A defective motherboard is not exchanged separately, but together with the PC.

10.9 Exchanging DIMM memory modules

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the PC cover.

2. Using your thumbs, carefully open the side tabs in the direction indicated by the arrows. The DIMM memory module is released and lifted out of its socket.
3. Press the new DIMM memory module into the slot in the DIMM socket until it clicks into position.
There are two asymmetrically positioned recesses on the underside of the DIMM memory modules; these must mate with the coding on the DIMM sock­et.
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Fig. 10-6: Exchanging DIMM memory modules
1 Side tabs 3 DIMM memory module socket 2 Asymmetrically positioned re-
cesses
10. Repair

10.10 Exchanging the batteries

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the cabinet door.

2. Unplug the battery connection cables.
3. Press the spring clamp to the left.
4. Take out both battery blocks.
Always exchange both battery blocks.
5. Insert the new battery blocks and lock them in place with the spring clamp.
6. Plug in the battery connection cables.
Caution!
Observe the battery polarity as shown in (>>> Fig. 10-7). Installing the bat­teries in the wrong position or with reversed polarity can damage the batter­ies, the KPS600 and the low-voltage power supply unit.
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Fig. 10-7: Connection example: Batteries
1 Spring clamp

Storage instruction In case of long-term storage, the batteries must be charged every 6 months to

avoid the risk of damage due to self-discharge.

10.11 Removal and installation of the CD-ROM drive (optional)

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the control cabinet door.

2. Remove the fastening screw of the drives holder.
3. Push the drives holder out to the left.
Make a note of the number of the pin (pin 1 or pin 40) connected to the side of the 40-strand interface cable marked in red.
4. Disconnect the power supply and data cable.
5. Remove the fastening screws at the side.
6. Push the CD-ROM drive out of the holder.
7. Configure the new CD-ROM drive as "master".
Further information can be found in the manufacturer documentation.
8. Push the CD-ROM drive into the holder and fasten it with 4 screws.
9. Connect the power supply and data cable.
10. Install the drives holder and fasten it with a screw.
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Fig. 10-8: Exchanging the CD-ROM drive
10. Repair
1 Fastening screw of the drives
holder
2 Fastening screws of the CD-
ROM drive

10.12 Removal and installation of the floppy disk drive (optional)

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the control cabinet door.

2. Remove the fastening screw of the drives holder.
3. Push the drives holder out to the left.
Make a note of the number of the pin (pin 1 or pin 34) connected to the side of the 34-strand interface cable marked in red.
4. Disconnect the power supply and data cable.
5. Remove the fastening screws at the side.
6. Push the floppy disk drive out of the holder.
7. Push the new floppy disk drive into the holder and fasten it with 4 screws.
8. Connect the power supply and data cable.
9. Install the drives holder and fasten it with the screw.
Fig. 10-9: Exchanging the floppy disk drive
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1 Fastening screw of the drives
holder
2 Fastening screws of the floppy
disk drive

10.13 Exchanging the hard drive

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the control cabinet door.

2. Open the PC chassis.
3. Release the retaining clip of the hard drive.
4. Disconnect the interface and power supply cables.
5. Exchange the hard drive for a new one.
6. Connect the interface and power supply cables.
7. Place the hard drive on the holder and fasten it with the retaining clip.
8. Close the PC housing and the control cabinet door.
9. Install the operating system and the KUKA System Software (KSS).
Fig. 10-10: Exchanging the hard drive
1 Retaining clip 2 Interface and power supply
cables

10.14 Exchanging the KVGA card

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the control cabinet door.

2. Open the PC chassis.
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3. Unplug the connections to the KVGA card.
4. Release the fastenings of the card and pull the card out of the slot.
5. Check the new card for mechanical damage, insert it into the slot and tight­en the fastening screws.
6. Plug in the connections to the card.

10.14.1 KVGA card settings

Precondition User group “Expert”

Windows interface (CTRL+ESC)

Procedure 1. Select the menu sequence Control Panel > Display > Properties > Sys-

tem Settings > Extended > Chips.
2. The following options are offered in the “Display Device” window:
CRT (external monitor) LCD (KCP operation) BOTH (both display options)
The graphics card driver file is “Chips XPm.sys”.
10. Repair

10.15 Exchanging the MFC3 card

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the control cabinet door.

2. Open the PC chassis.
3. Unplug the connections to the MFC3 and DSE-IBS-C33.
4. Release the fastenings of the card and pull the card out of the slot.
5. Unscrew the DSE-IBS-C33 from the MFC3 and unplug it.
6. Inspect the new MFC3 for mechanical damage. Plug on the DSE-IBS-C33 and screw it down.
7. Plug the MFC3 into its slot and tighten the fastening screws.
8. Plug in the connections to the card.

10.16 Exchanging the DSE-IBS-C33 card

Preconditions The robot controller must be switched off and secured to prevent unau-

thorized persons from switching it on again.
Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.

Procedure 1. Open the control cabinet door.

2. Open the PC chassis.
3. Unplug the connections to the MFC3 and DSE-IBS-C33.
4. Release the fastenings of the MFC3 card and pull the card out of the slot.
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10.17 Exchanging the KPS600

Preconditions The robot controller must be switched off and secured to prevent unau-

5. Unscrew the DSE-IBS-C33 from the MFC3 and unplug it.
6. Plug on the new DSE-IBS-C33 and screw it down.
7. Plug the MFC3 into its slot and tighten the fastening screws.
8. Plug in the connections to the card.
9. Switch on the robot controller and let it run up.
10. After initialization, the LED on the DSE-IBS-C33 should flash.
thorized persons from switching it on again.
The power cable must be de-energized. Observe the ESD guidelines. Wait 5 minutes until the intermediate circuit has discharged.
Caution!
Voltages in excess of 50 V (up to 600 V) can be present in the KPS, the KSDs and the intermediate-circuit connecting cables up to 5 minutes after the control cabinet has been switched off!

Procedure 1. Open the control cabinet door.

2. Unplug all connections to the KPS600.
3. Slacken the Allen screws.
4. Lift the KPS600 slightly, tip the top forwards and lift the KPS600 out of the holder.
5. Insert the new KPS600 into the lower holder, hook it on at the top and tight­en the fastening screws.
6. Plug in all the connections.
Fig. 10-11: Exchanging the KPS600
1 Allen screws 3 Tip the KPS600 forwards 2 Lift the KPS600 4 Lift the KPS600 out of the
holder

10.18 Exchanging the KPS-27

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. Observe the ESD guidelines.
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