KRC4-Operating Instructions en

Controller KUKA Roboter GmbH
KR C4; KR C4 CK
Operating Instructions
KR C4;
KR C4 CK
Issued: 05.10.2016
Version: BA KR C4 GI V16
KR C4; KR C4 CK
© Copyright 2016
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication: Pub BA KR C4 GI (PDF) en

Book structure: BA KR C4 GI V17.2
Version: BA KR C4 GI V16
2 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

Contents
Contents
1 Introduction .................................................................................................. 9
1.1 Industrial robot documentation ................................................................................... 9
1.2 Representation of warnings and notes ...................................................................... 9
1.3 Trademarks ................................................................................................................ 9
1.4 Terms used ................................................................................................................ 10
2 Purpose ........................................................................................................ 13
2.1 Target group .............................................................................................................. 13
2.2 Intended use .............................................................................................................. 13
3 Product description ..................................................................................... 15

3.1 Overview of the industrial robot ................................................................................. 15
3.2 Overview of the robot controller ................................................................................. 15
3.3 KUKA Power Pack ..................................................................................................... 17
3.4 KUKA Servo Pack ...................................................................................................... 17
3.5 Control PC ................................................................................................................. 17
3.6 Cabinet Control Unit ................................................................................................... 18
3.7 Safety Interface Board ............................................................................................... 19
3.8 Resolver Digital Converter ......................................................................................... 19
3.9 Controller System Panel ............................................................................................ 20
3.10 Low-voltage power supply ......................................................................................... 21
3.11 24 V external power supply ........................................................................................ 21
3.12 Batteries ..................................................................................................................... 21
3.13 Mains filter .................................................................................................................. 21
3.14 Bus devices ................................................................................................................ 21
3.14.1 KCB devices ......................................................................................................... 22
3.14.2 KSB devices and configuration variants ............................................................... 22
3.14.3 KEB devices and configuration variants ............................................................... 22
3.15 Connection panel interfaces ...................................................................................... 24
3.16 Control PC interfaces ................................................................................................. 25
3.16.1 Motherboard D2608-K interfaces .......................................................................... 26
3.17 KUKA smartPAD holder (optional) ............................................................................. 29
3.18 Set of rollers (optional) ............................................................................................... 30
3.19 Cabinet cooling .......................................................................................................... 30
3.20 Description of the space for integration of customer options ..................................... 31
4 Technical data .............................................................................................. 33

4.1 External 24 V power supply ....................................................................................... 35
4.2 Safety Interface Board ............................................................................................... 35
4.3 Dimensions of robot controller ................................................................................... 36
4.4 Minimum clearances, robot controller ........................................................................ 37
4.5 Swing range for cabinet door ..................................................................................... 38
4.6 Dimensions of the smartPAD holder (optional) .......................................................... 38
4.7 Dimensions of boreholes for floor mounting .............................................................. 39
4.8 Dimensions of boreholes for technology cabinet ....................................................... 39
Issued: 05.10.2016 Version: BA KR C4 GI V16 3 / 217

KR C4; KR C4 CK
4.9 Plates and labels ....................................................................................................... 39

4.10 REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/2006 42
5 Safety ............................................................................................................ 43
5.1 General ...................................................................................................................... 43
5.1.1 Liability ................................................................................................................. 43
5.1.2 Intended use of the industrial robot ...................................................................... 43
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 44
5.1.4 Terms used .......................................................................................................... 44
5.2 Personnel .................................................................................................................. 46
5.3 Workspace, safety zone and danger zone ................................................................ 47
5.3.1 Determining stopping distances ........................................................................... 47
5.4 Triggers for stop reactions ......................................................................................... 48
5.5 Safety functions ......................................................................................................... 48
5.5.1 Overview of the safety functions ........................................................................... 48
5.5.2 Safety controller ................................................................................................... 49
5.5.3 Selecting the operating mode ............................................................................... 49
5.5.4 “Operator safety” signal ........................................................................................ 50
5.5.5 EMERGENCY STOP device ................................................................................ 51
5.5.6 Logging off from the higher-level safety controller ................................................ 51
5.5.7 External EMERGENCY STOP device .................................................................. 52
5.5.8 Enabling device .................................................................................................... 52
5.5.9 External enabling device ...................................................................................... 53
5.5.10 External safe operational stop .............................................................................. 53
5.5.11 External safety stop 1 and external safety stop 2 ................................................. 53
5.5.12 Velocity monitoring in T1 ...................................................................................... 53
5.6 Additional protective equipment ................................................................................ 53
5.6.1 Jog mode .............................................................................................................. 53
5.6.2 Software limit switches ......................................................................................... 54
5.6.3 Mechanical end stops ........................................................................................... 54
5.6.4 Mechanical axis limitation (optional) ..................................................................... 54
5.6.5 Axis range monitoring (optional) ........................................................................... 54
5.6.6 Options for moving the manipulator without drive energy .................................... 55
5.6.7 Labeling on the industrial robot ............................................................................ 55
5.6.8 External safeguards ............................................................................................. 55
5.7 Overview of operating modes and safety functions ................................................... 56
5.8 Safety measures ........................................................................................................ 56
5.8.1 General safety measures ..................................................................................... 56
5.8.2 Transportation ...................................................................................................... 58
5.8.3 Start-up and recommissioning .............................................................................. 58
5.8.3.1 Checking machine data and safety configuration ............................................ 59
5.8.3.2 Start-up mode .................................................................................................. 60
5.8.4 Manual mode ........................................................................................................ 62
5.8.5 Simulation ............................................................................................................. 62
5.8.6 Automatic mode ................................................................................................... 63
5.8.7 Maintenance and repair ........................................................................................ 63
5.8.8 Decommissioning, storage and disposal .............................................................. 64
5.8.9 Safety measures for “single point of control” ........................................................ 64
5.9 Applied norms and regulations .................................................................................. 65

Contents
6 Planning ....................................................................................................... 69
6.1 Electromagnetic compatibility (EMC) ......................................................................... 69
6.2 Installation conditions ................................................................................................. 69
6.3 Connection conditions ................................................................................................ 70
6.4 Fastening the KUKA smartPAD holder (optional) ...................................................... 72
6.5 Overview of interfaces ............................................................................................... 72
6.6 Motor interfaces ......................................................................................................... 74
6.6.1 Motor connector Xxx, external axes X7.1, X7.2, X7.3 .......................................... 75
6.6.1.1 Motor connector X20 ....................................................................................... 76
6.6.1.2 Motor connector X20, KPP and KSP ............................................................... 76
6.6.1.3 Motor connectors X20.1 and X20.4 (heavy-duty robot) ................................... 77
6.6.1.4 Motor connector X7.1, external axis 1 ............................................................. 77
6.6.1.5 Motor connectors X7.1 and X7.2, external axes 1 and 2 ................................. 78
6.6.1.6 X7.1, X7.2, X7.3, motor connectors, external axes 1, 2, 3 .............................. 78
6.6.1.7 Motor connector X8 (heavy-palletizing duty robot, 4 axes) .............................. 79
6.6.1.8 Motor connector X20 (palletizing robot, 4 axes) .............................................. 79
6.6.1.9 Motor connectors X20.1 and X20.4 (heavy-duty robot, 5 axes) ...................... 80
6.6.1.10 Motor connector X20 (palletizing robot, 5 axes) .............................................. 80
6.6.1.11 Motor connector X81 (4 axes) ......................................................................... 81
6.6.1.13 Motor connector X7.1, external axis 1 (palletizing robot) ................................. 82
6.6.1.14 Connector pin allocation for motor connectors X7.1 and X7.2, external axes 1 and 2
(palletizing robot) .................................................................................................. 82
6.6.2 Multiple connector X81, single connectors X7.1 to X7.4 ...................................... 82
6.6.2.3 Motor connectors X81 and X7.1 (5 axes) ........................................................ 84
6.6.2.4 Motor connectors X81, X7.1 and X7.2 (6 axes) ............................................... 84
6.6.2.5 Motor connectors X81, X7.1...X7.3 (7 axes) .................................................... 85
6.6.2.6 Motor connectors X81, X7.1...X7.4 (8 axes) .................................................... 86
6.6.3 Single connectors X7.1 to X7.8 ............................................................................ 87
6.6.3.1 Motor connectors X7.1...X7.3 (3 axes) ............................................................ 87
6.7 Power supply connection via X1 Harting connector ................................................... 91
6.8 Discrete interfaces for safety options ......................................................................... 92
6.8.1 Description of safety interface X11 ....................................................................... 92
6.8.1.1 X11 connector contact diagram ....................................................................... 92
6.8.1.2 Safety interface X11 ........................................................................................ 92
6.8.1.3 X11 external enabling switch ........................................................................... 95
6.8.1.4 Wiring example for E-STOP circuit and safeguard .......................................... 96
6.8.1.5 Wiring examples for safe inputs and outputs ................................................... 97
6.9 Ethernet interfaces ..................................................................................................... 99
6.9.1 Safety functions via Ethernet safety interface ....................................................... 99
6.9.1.1 Schematic circuit diagram for enabling switches ............................................. 103
6.9.1.2 SafeOperation via Ethernet safety interface (optional) .................................... 104
6.9.1.3 X66 Ethernet interface (RJ45) ......................................................................... 107

KR C4; KR C4 CK
6.10 EtherCAT connection on the CIB .............................................................................. 108

6.11 PE equipotential bonding ........................................................................................... 108
6.12 Modifying the system configuration, exchanging devices .......................................... 110
6.13 Operator safety acknowledgement ............................................................................ 110
6.14 Performance level ...................................................................................................... 110
6.14.1 PFH values of the safety functions ....................................................................... 110
7 Transportation ............................................................................................. 113

7.1 Transportation using lifting tackle .............................................................................. 113
7.2 Transportation by fork lift truck .................................................................................. 114
7.3 Transportation by pallet truck .................................................................................... 116
7.4 Transportation with set of rollers (optional) ............................................................... 117
8 Start-up and recommissioning ................................................................... 119

8.1 Start-up overview ....................................................................................................... 119
8.2 Installing the robot controller ..................................................................................... 120
8.3 Connecting the connecting cables ............................................................................. 121
8.3.1 Data cables, X21 .................................................................................................. 122
8.4 Fastening the KUKA smartPAD holder (optional) ...................................................... 122
8.5 Plugging in the KUKA smartPAD ............................................................................... 122
8.6 Connecting the PE equipotential bonding ................................................................. 122
8.7 Power supply connection via X1 Harting connector .................................................. 123
8.8 Reversing the battery discharge protection measures .............................................. 123
8.9 Configuring and connecting safety interface X11 ...................................................... 124
8.11 Start-up mode ............................................................................................................ 125
8.12 Switching on the robot controller ............................................................................... 126
9 Operation ...................................................................................................... 127

9.1 KUKA smartPAD teach pendant ................................................................................ 127
9.1.1 Front view ............................................................................................................. 127
9.1.2 Rear view ............................................................................................................. 129
10 Maintenance ................................................................................................. 131

10.1 Maintenance symbols ................................................................................................ 131
10.2 Checking SIB relay outputs ....................................................................................... 133
10.3 Checking Extended SIB relay outputs ....................................................................... 133
10.4 Cleaning the robot controller ..................................................................................... 134
11 Repair ............................................................................................................ 135

11.1 Repair and procurement of spare parts ..................................................................... 135
11.2 Wiring example X11 .................................................................................................. 136
11.3 Exchanging the external fan ...................................................................................... 137
11.4 Exchanging the internal fan ....................................................................................... 138
11.5 Exchanging control PC components ......................................................................... 139
11.5.1 Exchanging the control PC ................................................................................... 139
11.5.2 Exchanging the control PC fan ............................................................................. 140
11.5.3 Exchanging the motherboard ............................................................................... 142
11.5.4 Exchanging the motherboard battery ................................................................... 142
11.5.5 Exchanging the LAN Dual NIC network card ........................................................ 142

Contents
11.5.6 Exchanging the hard drive .................................................................................... 143

11.6.1 Exchanging the KUKA Power Pack ...................................................................... 144
11.6.2 Exchanging the KUKA Servo Pack ....................................................................... 148
11.6.3 Exchanging the Cabinet Control Unit .................................................................... 150
11.6.4 Exchanging the Safety Interface Board ................................................................ 153
11.6.5 Exchanging the Resolver Digital Converter .......................................................... 156
11.7 Exchanging the batteries ........................................................................................... 158
11.7.1 Exchanging the batteries behind the cooling duct ................................................ 158
11.7.2 Exchanging the batteries in the cabinet door ........................................................ 161
11.8 Exchanging the low-voltage power supply unit .......................................................... 162
11.9 Exchanging the pressure relief plug ........................................................................... 163
11.10 Checking and exchanging the ballast resistors .......................................................... 164
11.11 Exchanging the mains filter ........................................................................................ 166
11.12 Installing the KUKA System Software (KSS) ............................................................ 169
12 Troubleshooting .......................................................................................... 171

12.1 Cabinet Control Unit LED display .............................................................................. 171
12.2 Cabinet Control Unit fusing ........................................................................................ 175
12.3 Cabinet Control Unit fusing (optional) ........................................................................ 176
12.4 Resolver Digital Converter LED display ..................................................................... 177
12.5 Controller System Panel LED display ........................................................................ 179
12.5.1 Controller System Panel LED error display .......................................................... 181
12.6 Control PC interfaces ................................................................................................. 181
12.6.1 LAN Onboard LED display on motherboard D2608-K .......................................... 182
12.7 Safety Interface Board LED display ........................................................................... 184
12.8 Safety Interface Board fuses ...................................................................................... 187
12.9 Checking the KUKA Servo Pack ................................................................................ 189
12.10 Checking the KUKA Power Pack ............................................................................... 190
12.11 Checking the KUKA Power Pack 3 ............................................................................ 192
12.12 KPP and KSP error messages ................................................................................... 192
12.13 KPP and KSP warning messages .............................................................................. 196
13 Decommissioning, storage and disposal .................................................. 201

13.1 Decommissioning ....................................................................................................... 201
13.2 Storage ...................................................................................................................... 201
13.3 Disposal ..................................................................................................................... 201
14 KUKA Service .............................................................................................. 203

14.1 Requesting support .................................................................................................... 203
14.2 KUKA Customer Support ........................................................................................... 203
Index ............................................................................................................. 211

KR C4; KR C4 CK

1 Introduction
1 Introduction
t
1.1 Industrial robot documentation

t
The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.2 Representation of warnings and notes
Safety These warnings are relevant to safety and must be observed.
These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.
These warnings mean that death or severe injuries may

occur, if no precautions are taken.
These warnings mean that minor injuries may occur, if

no precautions are taken.
These warnings mean that damage to property may oc-

cur, if no precautions are taken.
These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.
This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:
Procedures marked with this warning must be followed

exactly.
Notices These notices serve to make your work easier or contain references to further
information.
Tip to make your work easier or reference to further information.
1.3 Trademarks
 Windows is a trademark of Microsoft Corporation.
 EtherCAT® is a registered trademark and patented technol-

ogy, licensed by Beckhoff Automation GmbH, Germany.

KR C4; KR C4 CK
 CIP Safety® is a trademark of ODVA.
1.4 Terms used
Term Description
Br M{Number} Brake Motor{Number}
CCU Cabinet Control Unit
CIB Cabinet Interface Board
CIP Safety Common Industrial Protocol Safety
CIP Safety is an Ethernet/IP-based safety inter-
face for connecting a safety PLC to the robot
controller. (PLC = master, robot controller =
slave)
CK Customer-built Kinematics
CSP Controller System Panel
Display element and connection point for USB
and network
Dual NIC Dual Network Interface Card
Dual-port network card
EDS Electronic Data Storage (memory card)
EDS cool Electronic Data Storage (memory card) with
extended temperature range
EMD Electronic Mastering Device
EMC ElectroMagnetic Compatibility
Ethernet/IP Ethernet/Internet Protocol is an Ethernet-based
field bus.
HMI Human Machine Interface:
KUKA.HMI is the KUKA user interface.
KCB KUKA Controller Bus
KEB KUKA Extension Bus
KLI KUKA Line Interface
Connection to higher-level control infrastructure
(PLC, archiving)
KONI KUKA Option Network Interface
Interface for KUKA options
KPC KUKA control PC
KPP KUKA Power Pack
Drive power supply with drive controller
KRL KUKA Robot Language
KUKA programming language
KSB KUKA System Bus
A field bus for internal networking of the control-
lers

1 Introduction
Term Description
KSI KUKA Service Interface
Interface on the CSP on the control cabinet
The WorkVisual PC can either connect to the
robot controller via the KLI or it can be plugged
into the KSI.
KSP KUKA Servo Pack
Drive controller
KSS KUKA System Software
Manipulator The robot arm and the associated electrical
installations
M{Number} Motor {Number}
NA North America
PELV Protective Extra Low Voltage
External 24 V power supply
QBS Operator safety acknowledgment signal
RDC Resolver Digital Converter (KR C4)
RDC cool Resolver Digital Converter (KR C4) with
extended temperature range
RTS Request To Send
Transmission request signal
SATA connections Data bus for exchanging data between the pro-
cessor and the hard drive
SG FC Servo gun
SIB Safety Interface Board
SION Safety I/O Node
SOP SafeOperation
Option with software and hardware components
SPS (PLC) A Programmable Logic Controller
is used in systems as a higher-level master mod-
ule in the bus system
SRM SafeRangeMonitoring
Safety option with software and hardware com-
ponents
SSB SafeSingleBrake
Safety option
US1 Load voltage (24 V) not switched
US2 Load voltage (24 V) switched. Deactivates actu-
ators, for example, when the drives are deacti-
vated
USB Universal Serial Bus
Bus system for connecting additional devices to
a computer
EA External axis (linear unit, Posiflex)

KR C4; KR C4 CK

2 Purpose
2 Purpose
2
2.1 Target group

s
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 ob-
tained directly from our subsidiaries.
2.2 Intended use
Use The robot controller is intended solely for operating the following components:
 KUKA industrial robots
 KUKA linear units
 KUKA positioners
 Robot kinematic systems according to DIN EN ISO 10218-1
Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. This includes e.g.:
 Use as a climbing aid
 Operation outside the permissible operating parameters
 Use in potentially explosive environments
 Use in underground mining

KR C4; KR C4 CK

3 Product description
3.1
t
Overview of the industrial robot
s
The industrial robot consists of the following components:

 Manipulator
 Robot controller
 Teach pendant
 Connecting cables
 Software
 Options, accessories
Fig. 3-1: Example of an industrial robot
1 Manipulator 3 KUKA smartPAD

2 Robot controller 4 Connecting cables
3.2 Overview of the robot controller
The robot controller consists of the following components:

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

KR C4; KR C4 CK
Fig. 3-2: Overview of the robot controller, front view
1 Mains filter 8 Brake filter

2 Main switch 9 CCU
3 CSP 10 SIB/Extended SIB
4 Control PC 11 Fuse element
5 Drive power supply (drive con- 12 Batteries (positioning depend-
troller, optional) ing on variant)
6 Drive controller 13 Connection panel
7 Drive controller (optional) 14 KUKA smartPAD
Fig. 3-3: Overview of robot controller, rear view
1 KSP/KPP heat sink 4 External fan

2 Brake resistor 5 Low-voltage power supply unit
3 Heat exchanger

3.3 KUKA Power Pack
Description The KUKA Power Pack (KPP) is the drive power supply and generates a rec-
tified intermediate circuit voltage from an AC power supply. This intermediate
circuit voltage is used to supply the internal drive controllers and external
drives. There are 4 different device variants, all having the same size. There
are LEDs on the KPP which indicate the operating state.
 KPP without axis amplifier (KPP 600-20)
 KPP with amplifier for one axis (KPP 600-20-1x40)
Peak output current 1x40 A
 KPP with amplifier for two axes (KPP 600-20-2x40)
 KPP with amplifier for three axes (KPP 600-20-3x20)
 KPP with amplifier for one axis (KPP 600-20-1x64)
Functions The KPP has the following functions:

 KPP central AC power supply connection in interconnected operation
 Power output with 400 V supply voltage: 14 kW
 Rated current: 25 A DC
 Connection and disconnection of the supply voltage
 Powering of several axis amplifiers from the DC link
 Integrated brake chopper through connection of an external ballast resis-
tor
 Overload monitoring by the ballast resistor
 Stopping of synchronous servomotors by means of short-circuit braking
3.4 KUKA Servo Pack
Description The KUKA Servo Pack (KSP) is the drive controller for the manipulator axes.
There are 3 different device variants, all having the same size. There are LEDs
on the KSP which indicate the operating state.
 KSP for 3 axes (KSP 600-3x40)
Peak output current 3x 40 A
Functions The KSP has the following functions:

 Power range: 11 kW to 14 kW per axis amplifier
 Direct infeed of the DC intermediate circuit voltage
 Field-oriented control for servomotors: Torque control
3.5 Control PC
PC components The control PC (KPC) includes the following components:

 Power supply unit
 Motherboard
 Processor

KR C4; KR C4 CK
 Heat sink
 Memory modules
 Hard drive
 LAN Dual NIC network card (not present on all motherboard variants)
 PC fan
 Optional modules, e.g. field bus cards
Functions The control PC (KPC) is responsible for the following functions of the robot
controller:
 Graphical user interface
 Program creation, correction, archiving, and maintenance
 Sequence control
 Path planning
 Control of the drive circuit
 Monitoring
 Safety equipment
 Communication with external periphery (other controllers, host computers,
PCs, network)
3.6 Cabinet Control Unit
Description The Cabinet Control Unit (CCU) is the central power distributor and communi-
cation interface for all components of the robot controller. The CCU consists
of the Cabinet Interface Board (CIB) and the Power Management Board
(PMB). All data are transferred via this internal communication interface to the
controller for further processing. If the mains voltage fails, the control compo-
nents continue to be powered by batteries until the position data are saved and
the controller has shut down. The charge and quality of the batteries are
checked by means of a load test.
Functions  Communication interface for the components of the robot controller

 Safe inputs and outputs
 Control of main contactors 1 and 2
 Adjustment referencing (mastering test)
 KUKA smartPAD plugged in
 4 Fast Measurement inputs for customer applications
 Monitoring of the fans in the robot controller
 Fans
 Control PC fan
 Temperature sensing:
 Thermostatic switch for transformer
 Alarm contact for cooling unit
 Alarm contact for main switch
 Temperature sensor for ballast resistor
 Temperature sensor for internal cabinet temperature
 The following components are connected to the KPC via the KUKA Con-
troller Bus:
 KPP/KSP
 Resolver Digital Converter
 The following operator panels and service devices are connected to the
control PC via the KUKA System Bus:
 KUKA Operator Panel Interface

 Diagnostic LEDs
 Electronic Data Storage Interface
Power supply with battery backup
 KPP
 KSP
 KUKA smartPAD
 Multi-core control PC
 Controller System Panel (CSP)
 Resolver Digital Converter (RDC)
 Standard SIB or Standard and Extended SIB (optional)
Power supply without battery backup
 Motor brakes
 External fan
 Customer interface
3.7 Safety Interface Board
Description The Safety Interface Board (SIB) is an integral part of the safety interface. 2
different SIBs are used in the robot controller, the Standard SIB and the Ex-
tended SIB, depending on the configuration of the safety interface. The Stan-
dard SIB and the Extended SIB incorporate sensing, control and switching
functions. The Extended SIB can only be operated together with the Standard
SIB. The output signals are provided as electrically isolated outputs.
The Standard SIB contains the following safe inputs and outputs:
 5 safe inputs
 3 safe outputs
The Extended SIB contains the following safe inputs and outputs:
 8 safe inputs
 8 safe outputs
Functions The Standard SIB has the following functions:

 Safe inputs and outputs for the discrete safety interface of the robot con-
troller
The Extended SIB has the following functions:
 Safe inputs and outputs for range selection and range monitoring for the
SafeRobot option
or optionally
 Provision of signals for axis range monitoring
3.8 Resolver Digital Converter
Description The Resolver Digital Converter (RDC) is used to detect the motor position da-
ta. 8 resolvers can be connected to the RDC. In addition, the motor tempera-
tures are measured and evaluated. For non-volatile data storage, the EDS is
located in the RDC box.
2 different RDCs are used in the robot controller according to the specific cus-
tomer requirements:
 RDC
Temperature range: +5 ... 55 °C (278 ... 328 K)

KR C4; KR C4 CK
 RDC cool
Temperature range: -30 ... +55 °C (243 ... 328 K)
If an RDC cool is used, an EDS cool must also be used.
Functions The RDC has the following functions:

 Safe acquisition of up to 8 motor position data streams via resolver
 Detection of up to 8 motor operating temperatures
 Communication with the robot controller
 Monitoring of the resolver cables
 The following non-volatile data are stored on the EDS:
 Position data
 KUKA configuration
3.9 Controller System Panel
Description The Controller System Panel (CSP) is a display element for the operating state
and has the following connections:
 USB1
 USB2
 KLI (optional)
 KSI (optional)
Overview
Fig. 3-4: Arrangement of LEDs and connectors on CSP
Item Component Color Meaning

1 LED 1 Green Operating LED
2 LED 2 White Sleep LED
3 LED 3 White Automatic LED
4 USB 1 - -
5 USB 2 - -
6 RJ45 - KLI; KSI
7 LED 6 Red Error LED 3

3.10 Low-voltage power supply
Description The low-voltage power supply unit provides power to the components of the
robot controller.
A green LED indicates the operating state of the low-voltage power supply
unit.
3.11 24 V external power supply
External 24 V power supply is possible via the following interfaces:

 RoboTeam X57
 Interface X11
 Connector X55
Power supply to the KLI switch in the robot controller
The external power supply to the SIB and CIB boards cannot be isolated. If the
SIB is supplied externally, the CIB is also supplied externally, and vice versa.
3.12 Batteries
Description In the event of a power failure, or if the power is switched off, the batteries en-
able the robot controller to be shut down in a controlled manner. The batteries
are charged via the CCU and the charge is checked and indicated.
3.13 Mains filter
Description The mains filter (interference suppressor filter) suppresses interference volt-
ages on the power cable.
3.14 Bus devices
Overview
Fig. 3-5: Overview of bus devices

KR C4; KR C4 CK
1 KSP, left (optional) 9 KUKA Controller Bus (KCB)

2 KSP, middle 10 CCU
3 KPP 11 Standard/Extended SIB (optional)
4 LAN Dual NIC card 12 KSB
5 Ethernet motherboard 13 KUKA Extension Bus (KEB)
6 CSP 14 RDC
7 KSI/KLI 15 Electronic Mastering Device (EMD)
8 KUKA System Bus 16 KUKA smartPAD
(KSB)
3.14.1 KCB devices
KCB devices The KCB includes the following devices:

 KPP
 KSP, middle
 KSP, left
 RDC
 CIB
 EMD
3.14.2 KSB devices and configuration variants
KSB devices The KSB includes the following devices:

 CIB SION
 smartPAD SION
 Standard SIB (optional)
 Standard/Extended SIB (optional)
Configuration
variants
Application Config. CIB Standard SIB Extended SIB

Standard Safety without/with Variant 1 X - -
SOP via PROFIsafe
Standard Safety via interface Variant 2 X X -
Standard Safety with SOP via in- Variant 3 X X X
terface
Standard Safety without/with Variant 4 X - -
SOP via CIP Safety
3.14.3 KEB devices and configuration variants
KEB devices The following components can be KEB devices:

 PROFIBUS master
 PROFIBUS slave
 PROFIBUS master/slave
 Expansion of digital I/Os 16/16
 DeviceNet master
 DeviceNet slave
 DeviceNet master/slave

 Digital I/Os 16/16

 Digital I/Os 16/16/4
 Digital I/Os 32/32/4
 Digital/analog I/Os 16/16/2
 Additional digital I/Os 16/8, welding cabinet (optional)
 Digital/analog I/Os 32/32/4
 EtherCAT bridge master/master
Configuration
variants
Application Config. Bus

Connection of PROFIBUS devices Variant 1 PROFIBUS master
Connection to line PLC with PROFI- Variant 2 PROFIBUS slave
BUS interface
Connection of PROFIBUS devices Variant 3 PROFIBUS master/slave
Connection to line PLC with Profi-
bus interface
Connection of PROFIBUS devices Variant 4 PROFIBUS master Expansion of digital
I/Os 16/16
Connection of 16 dig. inputs and 16
dig. outputs with 0.5 A
Connection to line PLC with PROFI- Variant 5 PROFIBUS slave
BUS interface
Connection of PROFIBUS devices Variant 6 PROFIBUS mas-
ter/slave
Connection to line PLC with PROFI-
BUS interface
Connection of 16 dig. inputs and 16 Variant 7 Digital I/Os 16/16
Connection of 16 dig. inputs and 16 Variant 8 Digital I/Os 16/16/4
dig. outputs with 0.5 A / 4 dig. out-
puts with 2 A
Connection of 32 dig. inputs and 16 Variant 9 Digital I/Os 32/32/4
dig. outputs with 0.5 A / 4 dig. out-
puts with 2 A
VKR C2-compatible interface for Variant 10 Retrofit
connection to line PLC
Connection of EtherCAT devices Variant 11 -
Connection of DeviceNet devices Variant 12 DeviceNet master
Connection to line PLC with Devi- Variant 13 DeviceNet slave
ceNet interface
Connection of DeviceNet devices Variant 14 DeviceNet master/slave
Connection to line PLC with Devi-
ceNet interface

KR C4; KR C4 CK
Application Config. Bus

Connection of DeviceNet devices Variant 15 DeviceNet master Expansion of digital
I/Os 16/16
dig. outputs with 0.5 A.
Connection to line PLC with Devi- Variant 16 DeviceNet slave
ceNet interface
Connection of DeviceNet devices Variant 17 DeviceNet mas-
ter/slave
Connection to line PLC with Devi-
ceNet interface
Connection of 16 dig. inputs and 16 Variant 18 Expansion of digital and analog I/Os
dig. outputs with 0.5 A and 2 analog 16/16/2
inputs
Connection of 16 dig. inputs and 16 Variant 19 Expansion of digital I/Os 16/16/2 with addi-
dig. outputs with 0.5 A and 2 analog tional 16 digital inputs and 8 digital outputs
inputs and an additional 16 digital
inputs and 8 digital outputs
Connection of 32 dig. inputs and 16 Variant 20 Expansion of digital and analog I/Os
dig. outputs with 0.5 A and 4 analog 32/32/4
inputs
In the following cases a system modification must be carried out by the cus-
tomer using WorkVisual after connecting customer-specific devices to the cor-
responding interfaces:
 Connection of PROFIBUS devices
 Connection of EtherCAT devices
3.15 Connection panel interfaces
Overview The connection panel of the robot controller consists of connections for the fol-
lowing cables:
 Power cable / infeed
 Motor cables to the manipulator
 Data cables to the manipulator
 KUKA smartPAD cable
 PE cables
 Peripheral cables
The configuration of the connection panel varies according to the customer-
specific version and the options required.
Note The following safety interfaces can be configured in the robot controller:
 Discrete safety interface X11
 Ethernet safety interface X66
 PROFIsafe KLI or
 CIP Safety KLI
The discrete safety interface X11 and the Ethernet safety interface
X66 cannot be connected and used together.
Only one of the safety interfaces can be used at a time.

The configuration of the connection panel varies according to customer re-

quirements and options. In this documentation, the robot controller is de-
scribed with the maximum configuration.
Connection panel
Fig. 3-6: Connection panel overview
1 X1 Power supply connection

2 Motor connector interfaces
3 Option
4 Option
5 X11 Safety interface
6 Option
7 Option
8 X19 smartPAD connection
9 X42 optional
10 X21 RDC connection
11 X66 Ethernet safety interface
12 PE1 Ground conductor to manipulator
13 PE2 Ground conductor to main infeed
Only safety interface X11 or Ethernet safety interface X66 (PRO-

FIsafe/CIP Safety) can be configured.
The optional interfaces are described in the assembly and operating

instructions “Optional Interfaces”.
All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor di-
odes. RC elements and VCR resistors are not suitable.
3.16 Control PC interfaces
Motherboards The following motherboard variants can be installed in the control PC:
 D2608-K
 D3076-K
 D3236-K

KR C4; KR C4 CK
3.16.1 Motherboard D2608-K interfaces
Overview
Fig. 3-7: Motherboard D2608-K interfaces
1 Connector X961, power supply DC 24 V

2 Connector X962, PC fan
3 LAN Dual NIC – KUKA Controller Bus
4 LAN Dual NIC – KUKA Line Interface
5 Field bus cards, slots 1 to 7
6 LAN Onboard – KUKA System Bus
7 8 USB 2.0 ports
KUKA Roboter GmbH has assembled, tested and supplied the moth-
erboard with an optimum configuration. No liability will be accepted
for modifications to the configuration that have not been carried out
by KUKA Roboter GmbH.
Slot assignment
Fig. 3-8: Slot assignment, motherboard D2608-K
Slot Type Plug-in card

1 PCI Field bus
2 PCI Field bus
3 PCIe LAN Dual NIC


4 PCIe Not assigned
5 PCIe Not assigned
6 PCI Field bus
7 PCIe Not assigned
Overview

4 LAN Dual NIC – KUKA Controller Bus
5 LAN Dual NIC – KUKA System Bus
6 4 USB 2.0 ports
7 DVI-I (VGA support possible via DVI on VGA adapter). The user inter-
face of the controller can only be displayed on an external monitor if
no active operator control device (smartPAD, VRP) is connected to
the controller.
8 4 USB 2.0 ports
9 LAN Onboard – KUKA Option Network Interface
10 LAN Onboard – KUKA Line Interface

KR C4; KR C4 CK
Slot assignment

1 PCI Field bus
2 PCI Field bus
3 PCI Field bus
4 PCI Field bus
5 PCIe Not assigned
6 PCIe Not assigned
7 PCIe LAN Dual NIC network card
Overview

(optional, inside PC, depending on variant)
4 LAN Onboard – KUKA Controller Bus
5 LAN Onboard – KUKA System Bus
6 2 USB 2.0 ports

7 2 USB 3.0 ports

8 DVI-I
9 4 USB 2.0 ports
10 LAN Onboard – KUKA Option Network Interface
11 LAN Onboard – KUKA Line Interface
VGA support is possible via DVI on VGA adapter. The user interface
of the controller can only be displayed on an external monitor if no ac-
tive operator control device (smartPAD, VRP) is connected to the
controller.
Slot assignment

1 PCI Field bus
2 PCI Field bus
3 - Not available
4 - Not available
5 - Not available
6 - Not available
7 - Not available
3.17 KUKA smartPAD holder (optional)
Description The optional KUKA smartPAD holder can be used to hang up the smartPAD
and its connecting cable on the door of the robot controller or on the safety
fence.

KR C4; KR C4 CK
Overview
Fig. 3-13: KUKA smartPAD holder
1 KUKA smartPAD holder 3 Front view

2 Side view
3.18 Set of rollers (optional)
Description The set of rollers is designed for installation on the cabinet base or fork slots
of KR C4 robot controllers. The set of rollers enables the robot controller to be
easily rolled out of and into a bank of cabinets.
Fig. 3-14: Set of rollers
1 Castors with brake 3 Rear cross-strut

2 Castors without brake 4 Front cross-strut
3.19 Cabinet cooling
Description The control cabinet is divided into two cooling circuits. The inner zone, con-
taining the control and power electronics, is cooled by a heat exchanger. In the
outer zone, the ballast resistor and the heat sinks of the KPP and KSP are
cooled directly by ambient air.
Upstream installation of filter mats at the ventilation slits

causes an increase in temperature, leading to a reduc-
tion in the service life of the installed devices!

Configuration
Fig. 3-15: Cooling circuits
1 Air inlet, external fan 6 Air outlet for heat exchanger

2 Heat sink, low-voltage power 7 Air outlet for mains filter
supply
3 Air outlet, KPP 8 Heat exchanger
4 Air outlet, KSP 9 KPC intake duct or internal fan
5 Air outlet, KSP 10 PC fan
3.20 Description of the space for integration of customer options
Overview The space for integration of customer options can be used for external cus-
tomer equipment depending on the installed hardware options on the top-hat
rail.
Fig. 3-16: Space for integration of customer components
1 Space for integration of customer options

KR C4; KR C4 CK

4 Technical data
4 Technical data
4
Basic data Cabinet type KR C4

Number of axes max. 9
t
Weight (without transformer) 150 kg
Protection rating IP 54
Sound level according to average: 67 dB (A)
DIN 45635-1
Installation with other cabinets Side-by-side, clearance 50 mm
(with/without cooling unit)
Load on cabinet roof with even dis- 1,500 N
tribution
Power supply
If the robot controller is connected to a power system
connection without a grounded neutral or is operated with incorrect
machine data, this may cause malfunctions in the robot controller and mate-
rial damage to the power supply units. Electrical voltage can cause injuries.
The robot controller may only be operated with grounded-neutral power sup-
ply systems.
If no grounded neutral is available, or if the mains voltage differs from those

specified here, a transformer must be used.
Rated supply voltage according to AC 3x380 V, AC 3x400 V,

the machine data, optionally: AC 3x440 V or AC 3x480 V
Permissible tolerance of rated sup- Rated supply voltage ±10%
ply voltage
Mains frequency 49 … 61 Hz
System impedance up to the con- ≤ 300 mΩ
nection point of the robot controller
Ground leakage current up to 300 mA
Full-load current See rating plate
Mains-side fusing without trans- min. 3x25 A, slow-blowing
former
Mains-side fusing with transformer min. 3x32 A, slow-blowing, with
13 kVA
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit.
Environmental Ambient temperature during opera- +5 ... 45 °C (278 ... 318 K)

conditions tion without cooling unit
Ambient temperature during opera- +5 ... 50 °C (293 ... 323 K)
tion with cooling unit
Ambient temperature during stor- -25 ... +40 °C (248 ... 313 K)
age/transportation with batteries
Ambient temperature during stor- -25 ... +70 °C (248 ... 343 K)
age/transportation without batteries
Temperature change max. 1.1 K/min

KR C4; KR C4 CK
Humidity class 3k3 acc. to DIN EN 60721-3-3;

1995
Altitude  up to 1000 m above mean sea
level with no reduction in power
 1000 m ... 4000 m above mean
sea level with a reduction in
power of 5%/1000 m
To prevent exhaustive discharge and thus destruction of

the batteries, the batteries must be recharged at regular
intervals according to the storage temperature.
If the storage temperature is +20 °C or lower, the batteries must be re-
charged every 9 months.
If the storage temperature is between +20 °C and +30 °C, the batteries must
be recharged every 6 months.
Vibration resis-
During transpor- During continuous
tance Type of loading
tation operation
r.m.s. acceleration (sus- 0.37 g 0.1 g
tained oscillation)
Frequency range (sustained 4...120 Hz
oscillation)
Acceleration (shock in X/Y/Z 10 g 2.5 g
direction)
Waveform/duration (shock Half-sine/11 ms
in X/Y/Z direction)
If more severe mechanical stress is expected, the controller must be installed

on anti-vibration components.
Control unit Supply voltage DC 27.1 V ± 0.1 V
Control PC Main processor See shipping version

DIMM memory modules See shipping version (min. 2 GB)
Hard drive See shipping version
KUKA smartPAD Supply voltage 20 … 27.1 V DC

Dimensions (WxHxD) approx. 24x29x5 cm3
Display Touch-sensitive color display
600 x 800 pixels
Display size 8.4"
Interfaces USB
Weight 1.1 kg
Protection rating (without USB stick IP 54
and USB connection closed with a
plug)
Space for
Designation Values
integration of
Power dissipation of installed com- max. 20 W
customer options
ponents
Depth of installed components approx. 200 mm

4 Technical data
Designation Values
Width 300 mm
Height 150 mm
Cable lengths For cable designations, standard lengths and optional lengths, please refer to
the operating instructions or assembly instructions of the manipulator and/or
the assembly and operating instructions for KR C4 external cabling for robot
controllers.
When using smartPAD cable extensions, only two extensions may be

used. An overall cable length of 50 m must not be exceeded.
The difference in the cable lengths between the individual channels

of the RDC box must not exceed 10 m.
4.1 External 24 V power supply
PELV external External voltage PELV power supply unit acc. to EN

power supply 60950 with rated voltage 27 V (18 V
... 30 V), safely isolated
Continuous current >8A
Cable cross-section of power sup- ≥ 1 mm2
ply cable
Cable length of power supply cable < 50 m, or < 100 m wire length (out-
going and incoming lines)
The cables of the power supply unit must not be routed together with
power-carrying cables.
The minus connection of the external voltage must be grounded by

the customer.
Parallel connection of a basic-insulated device is not permitted.
4.2 Safety Interface Board
SIB outputs
The power contacts must only be fed from a safely isolated PELV
power supply unit. (>>> 4.1 "External 24 V power supply" Page 35)
Operating voltage, power contacts ≤ 30 V

Current via power contact min. 10 mA
< 750 mA
Cable lengths (connection of actua- < 50 m cable lengths
tors)
< 100 m wire length (outgoing and
incoming lines)
Cable cross-section (connection of ≥ 1 mm2
actuators)

KR C4; KR C4 CK
Switching cycles, Standard SIB Service life: 20 years

< 100,000 (corresponds to 13
switching cycles per day)
Switching cycles, Extended SIB Service life: 20 years
< 780,000 (corresponds to 106
switching cycles per day)
The module must be exchanged when the number of switching cycles is ex-
ceeded.
SIB inputs Switching level of the inputs The state for the inputs is not
defined for the voltage range from
5 V to 11 V (transition range). Either
the ON state or the OFF state is set.
OFF state for the voltage range
from -3 V to 5 V (OFF range).
ON state for the voltage range from
11 V to 30 V (ON range).
Load current with 24 V supply volt- > 10 mA
age
Load current with 18 V supply volt- > 6.5 mA
age
Max. load current < 15 mA
Cable length, terminal - sensor < 50 m, or < 100 m wire length (out-
Cable cross-section, test output - > 0.5 mm2
input connection
Capacitive load for the test outputs < 200 nF
per channel
Resistive load for the test outputs < 33 Ω
per channel
Test outputs A and B are sustained short-circuit proof.

The specified currents flow via the contact element connected to the
input. This must be rated for the maximum current of 15 mA.
4.3 Dimensions of robot controller
The dimensions of the robot controller are indicated in the diagram

(>>> Fig. 4-1 ).

4 Technical data
Fig. 4-1: Dimensions
1 Front view
2 Side view
3 Top view
4.4 Minimum clearances, robot controller
The minimum clearances that must be maintained for the robot controller are
indicated in the diagram (>>> Fig. 4-2 ).
Fig. 4-2: Minimum clearances
If the minimum clearances are not maintained, this can

result in damage to the robot controller. The specified
minimum clearances must always be observed.

KR C4; KR C4 CK
Certain maintenance and repair tasks on the robot controller

(>>> 10 "Maintenance" Page 131) (>>> 11 "Repair" Page 135) must
be carried out from the side or from the rear. The robot controller must
be accessible for this. If the side or rear panels are not accessible, it must be
possible to move the robot controller into a position in which the work can be
carried out.
4.5 Swing range for cabinet door
The diagram (>>> Fig. 4-3 ) shows the swing range for the door.
Fig. 4-3: Swing range for cabinet door
Swing range, standalone cabinet:

 Door with computer frame approx. 180°
Swing range, butt-mounted cabinets:
 Door approx. 155°
4.6 Dimensions of the smartPAD holder (optional)
The diagram (>>> Fig. 4-4 ) shows the dimensions and drilling locations for
mounting on the robot controller or safety fence.
Fig. 4-4: Dimensions and drilling locations for smartPAD holder

4 Technical data
4.7 Dimensions of boreholes for floor mounting
The dimensions of the boreholes for floor mounting are indicated in the dia-
gram (>>> Fig. 4-5 ).
Fig. 4-5: Boreholes for floor mounting
1 View from below
4.8 Dimensions of boreholes for technology cabinet
The diagram (>>> Fig. 4-6 ) shows the dimensions of the boreholes on the
KR C4 for fastening the technology cabinet.
Fig. 4-6: Fastening the technology cabinet
1 View from above
4.9 Plates and labels
Overview The following plates and labels (>>> Fig. 4-7 ) are attached to the robot con-
troller. They must not be removed or rendered illegible. Illegible plates and la-
bels must be replaced.

KR C4; KR C4 CK
Fig. 4-7: Plates and labels
The plates may vary slightly from the examples illustrated above de-
pending on the specific cabinet type or as a result of updates.
Item Description
1
Robot controller rating plate

2
Hot surface
During operation of the controller, surface temperatures may be
reached that could result in burn injuries. Protective gloves must be
worn!
3
Crushing hazard
Installation of the rear panel poses a crushing hazard. Protective
gloves must be worn!

4 Technical data
Item Description
4
KR C4 main switch
5
Danger due to residual voltage

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

The operating instructions and safety regulations must be read and
understood before work is carried out on the robot controller.

KR C4; KR C4 CK
Item Description
7
Control PC rating plate

8
High leakage current
4.10 REACH duty to communicate information acc. to Art. 33 of Regulation (EC)

1907/2006
On the basis of the information provided by our suppliers, the following com-
ponents of this product contain substances included on the Candidate List of
Substances of Very High Concern (SVHCs) in a concentration exceeding 0.1
percent by mass. None of these substances are released under normal and
reasonably foreseeable conditions of use.
Product REACH candidate/SVHC substance name CAS number

CR 2032 button cell 1,2-Dimethoxyethane; Ethylene glycol dimethyl 110-71-4
ether (EGDME)

5 Safety
5 Safety
f
5.1 General
y
5.1.1 Liability
The device described in this document is either an industrial robot or a com-

ponent thereof.
Components of the industrial robot:
 Manipulator
 Robot controller
 Teach pendant
 Connecting cables
 External axes (optional)
e.g. linear unit, turn-tilt table, positioner
 Software
 Options, accessories
The industrial robot is built using state-of-the-art technology and in accor-
dance with the recognized safety rules. Nevertheless, misuse of the industrial
robot may constitute a risk to life and limb or cause damage to the industrial
robot and to other material property.
The industrial robot may only be used in perfect technical condition in accor-
dance with its designated use and only by safety-conscious persons who are
fully aware of the risks involved in its operation. Use of the industrial robot is
subject to compliance with this document and with the declaration of incorpo-
ration supplied together with the industrial robot. Any functional disorders af-
fecting safety must be rectified immediately.
Safety infor- Safety information cannot be held against KUKA Roboter GmbH. Even if all
mation safety instructions are followed, this is not a guarantee that the industrial robot
will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the autho-
rization of KUKA Roboter GmbH. Additional components (tools, software,
etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus-
trial robot. The user is liable for any damage these components may cause to
the industrial robot or to other material property.
In addition to the Safety chapter, this document contains further safety instruc-
tions. These must also be observed.
5.1.2 Intended use of the industrial robot
The industrial robot is intended exclusively for the use designated in the “Pur-
pose” chapter of the operating instructions or assembly instructions.
Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. The manufacturer is not liable for any damage resulting
from such misuse. The risk lies entirely with the user.
Operation of the industrial robot in accordance with its intended use also re-
quires compliance with the operating and assembly instructions for the individ-
ual components, with particular reference to the maintenance specifications.
and is not allowed. This includes e.g.:

KR C4; KR C4 CK
 Transportation of persons and animals

 Use as a climbing aid
 Operation outside the specified operating parameters
 Use in potentially explosive environments
 Operation without additional safeguards
 Outdoor operation
 Underground operation
5.1.3 EC declaration of conformity and declaration of incorporation
The industrial robot constitutes partly completed machinery as defined by the

EC Machinery Directive. The industrial robot may only be put into operation if
the following preconditions are met:
 The industrial robot is integrated into a complete system.
or: The industrial robot, together with other machinery, constitutes a com-
plete system.
or: All safety functions and safeguards required for operation in the com-
plete machine as defined by the EC Machinery Directive have been added
to the industrial robot.
 The complete system complies with the EC Machinery Directive. This has
been confirmed by means of a conformity assessment procedure.
EC declaration of The system integrator must issue an EC declaration of conformity for the com-
conformity plete system in accordance with the Machinery Directive. The EC declaration
of conformity forms the basis for the CE mark for the system. The industrial
robot must always be operated in accordance with the applicable national
laws, regulations and standards.
The robot controller has a CE mark in accordance with the EMC Directive and
the Low Voltage Directive.
Declaration of The partly completed machinery is supplied with a declaration of incorporation

incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The
assembly instructions and a list of essential requirements complied with in ac-
cordance with Annex I are integral parts of this declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly com-
pleted machinery is not allowed until the partly completed machinery has been
incorporated into machinery, or has been assembled with other parts to form
machinery, and this machinery complies with the terms of the EC Machinery
Directive, and the EC declaration of conformity is present in accordance with
Annex II A.
5.1.4 Terms used
STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204-
1:2006.
Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may move.
The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance
The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived from
the individual axis ranges.

5 Safety
Term Description
User The user of the industrial robot can be the management, employer or
delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distances
of the manipulator and external axes (optional).
Service life The service life of a safety-relevant component begins at the time of
delivery of the component to the customer.
The service life is not affected by whether the component is used or not,
as safety-relevant components are also subject to aging during storage.
KUKA smartPAD see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safe operational stop The safe operational stop is a standstill monitoring function. It does not
stop the robot motion, but monitors whether the robot axes are station-
ary. If these are moved during the safe operational stop, a safety stop
STOP 0 is triggered.
The safe operational stop can also be triggered externally.
When a safe operational stop is triggered, the robot controller sets an
output to the field bus. The output is set even if not all the axes were sta-
tionary at the time of triggering, thereby causing a safety stop STOP 0 to
be triggered.
Safety STOP 0 A stop that is triggered and executed by the safety controller. The safety
controller immediately switches off the drives and the power supply to
the brakes.
Note: This stop is called safety STOP 0 in this document.
Safety STOP 1 A stop that is triggered and monitored by the safety controller. The brak-
ing operation is carried out by the non-safety-oriented section of the
robot controller and monitored by the safety controller. As soon as the
manipulator is has stopped, the safety controller deactivates the drives
and the power supply of the brakes.
When a safety STOP 1 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 1 can also be triggered externally.
Safety STOP 2 A stop that is triggered and monitored by the safety controller. The brak-
ing operation is carried out by the non-safety-oriented section of the
robot controller and monitored by the safety controller. The drives
remain activated and the brakes released. As soon as the manipulator is
at a standstill, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 2 can also be triggered externally.
Safety options Generic term for options which make it possible to configure additional
safe monitoring functions in addition to the standard safety functions.
Example: SafeOperation
smartPAD Programming device for the robot controller
The smartPAD has all the operator control and display functions
required for operating and programming the industrial robot.

KR C4; KR C4 CK
Term Description
Stop category 0 The drives are deactivated immediately and the brakes are applied. The
manipulator and any external axes (optional) perform path-oriented
braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-main-
taining braking.
 Operating mode T1: The drives are deactivated as soon as the robot
has stopped, but no later than after 680 ms.
 Operating mode T2, AUT (not available for VKR C4), AUT EXT: The
drives are switched off after 1.5 s.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a path-
maintaining braking ramp.
System integrator The system integrator is responsible for safely integrating the industrial
(plant integrator) robot into a complete system and commissioning it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Motion axis which is not part of the manipulator but which is controlled
using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.
5.2 Personnel
The following persons or groups of persons are defined for the industrial robot:
 User
 Personnel
All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.
User The user must observe the labor laws and regulations. This includes e.g.:
 The user must comply with his monitoring obligations.
 The user must carry out briefing at defined intervals.
Personnel Personnel must be instructed, before any work is commenced, in the type of
work involved and what exactly it entails as well as any hazards which may ex-
ist. Instruction must be carried out regularly. Instruction is also required after
particular incidents or technical modifications.
Personnel includes:
 System integrator
 Operators, subdivided into:
 Start-up, maintenance and service personnel
 Operating personnel
 Cleaning personnel
Installation, exchange, adjustment, operation, maintenance and re-

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

5 Safety
System integrator The industrial robot is safely integrated into a complete system by the system
integrator.
The system integrator is responsible for the following tasks:
 Installing the industrial robot
 Connecting the industrial robot
 Performing risk assessment
 Implementing the required safety functions and safeguards
 Issuing the EC declaration of conformity
 Attaching the CE mark
 Creating the operating instructions for the system
Operator The operator must meet the following preconditions:

 The operator must be trained for the work to be carried out.
 Work on the industrial robot must only be carried out by qualified person-
nel. These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are able
to assess the work to be carried out and detect any potential hazards.
Work on the electrical and mechanical equipment of the industrial ro-

bot may only be carried out by specially trained personnel.
5.3 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 safeguards (e.g. safety gate) must be situated inside the safety zone. In
the case of a stop, the manipulator and external axes (optional) are braked
and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of the
manipulator and external axes (optional). It must be safeguarded by means of
physical safeguards to prevent danger to persons or the risk of material dam-
age.
5.3.1 Determining stopping distances
The system integrator’s risk assessment may indicate that the stopping dis-
tances must be determined for an application. In order to determine the stop-
ping distances, the system integrator must identify the safety-relevant points
on the programmed path.
When determining the stopping distances, the robot must be moved with the
tool and loads which are also used in the application. The robot must be at op-
erating temperature. This is the case after approx. 1 h in normal operation.
During execution of the application, the robot must be stopped at the point
from which the stopping distance is to be calculated. This process must be re-
peated several times with a safety stop 0 and a safety stop 1. The least favor-
able stopping distance is decisive.
A safety stop 0 can be triggered by a safe operational stop via the safety inter-
face, for example. If a safety option is installed, it can be triggered, for in-
stance, by a space violation (e.g. the robot exceeds the limit of an activated
workspace in Automatic mode).
A safety stop 1 can be triggered by pressing the EMERGENCY STOP device
on the smartPAD, for example.

KR C4; KR C4 CK
5.4 Triggers for stop reactions
Stop reactions of the industrial robot are triggered in response to operator ac-
tions or as a reaction to monitoring functions and error messages. The follow-
ing table shows the different stop reactions according to the operating mode
that has been set.
Trigger T1, T2 AUT, AUT EXT

Start key released STOP 2 -
STOP key pressed STOP 2
Drives OFF STOP 1
“Motion enable” input STOP 2
drops out
Power switched off via STOP 0
main switch or power fail-
ure
Internal error in non- STOP 0 or STOP 1
safety-oriented part of the
(dependent on the cause of the error)
robot controller
Operating mode changed Safety stop 2
during operation
Safety gate opened (oper- - Safety stop 1
ator safety)
Enabling switch released Safety stop 2 -
Enabling switch pressed Safety stop 1 -
fully down or error
E-STOP pressed Safety stop 1
Error in safety controller Safety stop 0
or periphery of the safety
controller
5.5 Safety functions
5.5.1 Overview of the safety functions
The following safety functions are present in the industrial robot:

 Selecting the operating mode
 Operator safety (= connection for the monitoring of physical safeguards)
 EMERGENCY STOP device
 Enabling device
 External safe operational stop
 External safety stop 1
 Velocity monitoring in T1
The safety functions of the industrial robot meet the following requirements:
 Category 3 and Performance Level d in accordance with EN ISO 13849-
1
The requirements are only met on the following condition, however:
 The EMERGENCY STOP device is pressed at least once every 12
months.
The following components are involved in the safety functions:

5 Safety
 Safety controller in the control PC

 KUKA smartPAD
 Cabinet Control Unit (CCU)
 Resolver Digital Converter (RDC)
 KUKA Power Pack (KPP)
 KUKA Servo Pack (KSP)
 Safety Interface Board (SIB) (if used)
There are also interfaces to components outside the industrial robot and to
other robot controllers.
In the absence of operational safety functions and safe-

guards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deacti-
vated, the industrial robot may not be operated.
During system planning, the safety functions of the overall system

must also be planned and designed. The industrial robot must be in-
tegrated into this safety system of the overall system.
5.5.2 Safety controller
The safety controller is a unit inside the control PC. It links safety-relevant sig-
nals and safety-relevant monitoring functions.
Safety controller tasks:
 Switching off the drives; applying the brakes
 Monitoring the braking ramp
 Standstill monitoring (after the stop)
 Evaluation of safety-relevant signals
 Setting of safety-oriented outputs
5.5.3 Selecting the operating mode
Operating modes The industrial robot can be operated in the following modes:
 Manual Reduced Velocity (T1)
 Manual High Velocity (T2)
 Automatic (AUT)
 Automatic External (AUT EXT)
Do not change the operating mode while a program is running. If the

operating mode is changed during program execution, the industrial
robot is stopped with a safety stop 2.

KR C4; KR C4 CK
Operat-
Use Velocities
ing mode
 Program verification:
Programmed velocity, maxi-
For test operation, pro- mum 250 mm/s
T1 gramming and teach-
 Jog mode:
ing
Jog velocity, maximum
250 mm/s
 Program verification:
T2 For test operation Programmed velocity
 Jog mode: Not possible
For industrial robots  Program mode:
AUT without higher-level Programmed velocity
controllers  Jog mode: Not possible
For industrial robots  Program mode:
AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC  Jog mode: Not possible
Mode selector The user can change the operating mode via the connection manager. The
switch connection manager is a view that is called by means of the mode selector
switch on the smartPAD.
The mode selector switch may be one of the following variants:
 With key
It is only possible to change operating mode if the key is inserted.
 Without key
If the smartPAD is fitted with a switch without a key:

An additional device must be present to ensure that the
relevant functions cannot be executed by all users, but only by a restricted
group of people.
The device itself must not trigger motions of the industrial robot or other haz-
ards. If this device is missing, death or severe injuries may result.
The system integrator is responsible for ensuring that such a device is imple-
mented.
5.5.4 “Operator safety” signal
The “operator safety” signal is used for monitoring physical safeguards, e.g.
safety gates. Automatic operation is not possible without this signal. In the
event of a loss of signal during automatic operation (e.g. safety gate is
opened), the manipulator stops with a safety stop 1.
Operator safety is not active in modes T1 (Manual Reduced Velocity) and T2
(Manual High Velocity).

5 Safety
Following a loss of signal, automatic operation may only

be resumed when the safeguard has been closed and
when the closing has been acknowledged. This acknowledgement is to pre-
vent automatic operation from being resumed inadvertently while there are
still persons in the danger zone, e.g. due to the safety gate closing acciden-
tally.
The acknowledgement must be designed in such a way that an actual check
of the danger zone can be carried out first. Other acknowledgement functions
(e.g. an acknowlegement which is automatically triggered by closure of the
safeguard) are not permitted.
The system integrator is responsible for ensuring that these criteria are met.
Failure to met them may result in death, severe injuries or considerable dam-
age to property.
5.5.5 EMERGENCY STOP device
The EMERGENCY STOP device for the industrial robot is the EMERGENCY
STOP device on the smartPAD. The device must be pressed in the event of a
hazardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP device is pressed:
 The manipulator and any external axes (optional) are stopped with a safe-
ty stop 1.
Before operation can be resumed, the EMERGENCY STOP device must be
turned to release it.
Tools and other equipment connected to the manipulator

must be integrated into the EMERGENCY STOP circuit
on the system side if they could constitute a potential hazard.
Failure to observe this precaution may result in death, severe injuries or con-
siderable damage to property.
There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the smartPAD is disconnected.
(>>> 5.5.7 "External EMERGENCY STOP device" Page 52)
5.5.6 Logging off from the higher-level safety controller
If the robot controller is connected to a higher-level safety controller, this con-

nection will inevitably be terminated in the following cases:
 Switching off the voltage via the main switch of the robot
Or power failure
 Shutdown of the robot controller via the smartHMI
 Activation of a WorkVisual project in WorkVisual or directly on the robot
controller
 Changes to Start-up > Network configuration
 Changes to Configuration > Safety configuration
 I/O drivers > Reconfigure
 Restoration of an archive
Effect of the interruption:
 If a discrete safety interface is used, this triggers an EMERGENCY STOP
for the overall system.

KR C4; KR C4 CK
 If the Ethernet interface is used, the KUKA safety controller generates a

signal that prevents the higher-level controller from triggering an EMER-
GENCY STOP for the overall system.
If the Ethernet safety interface is used: In his risk assessment, the

system integrator must take into consideration whether the fact that
switching off the robot controller does not trigger an EMERGENCY
STOP of the overall system could constitute a hazard and, if so, how this haz-
ard can be countered.
Failure to take this into consideration may result in death, injuries or damage
to property.
If a robot controller is switched off, the E-STOP device on

the smartPAD is no longer functional. The user is re-
sponsible for ensuring that the smartPAD is either covered or removed from
the system. This serves to prevent operational and non-operational EMER-
GENCY STOP devices from becoming interchanged.
Failure to observe this precaution may result in death, injuries or damage to
property.
5.5.7 External EMERGENCY STOP device
Every operator station that can initiate a robot motion or other potentially haz-
ardous situation must be equipped with an EMERGENCY STOP device. The
system integrator is responsible for ensuring this.
There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the smartPAD is disconnected.
External EMERGENCY STOP devices are connected via the customer inter-
face. External EMERGENCY STOP devices are not included in the scope of
supply of the industrial robot.
5.5.8 Enabling device
The enabling devices of the industrial robot are the enabling switches on the
smartPAD.
There are 3 enabling switches installed on the smartPAD. The enabling
switches have 3 positions:
 Not pressed
 Center position
 Panic position
In the test modes, the manipulator can only be moved if one of the enabling
switches is held in the central position.
 Releasing the enabling switch triggers a safety stop 2.
 Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
 It is possible to hold 2 enabling switches in the center position simultane-
ously for up to 15 seconds. This makes it possible to adjust grip from one
enabling switch to another one. If 2 enabling switches are held simultane-
ously in the center position for longer than 15 seconds, this triggers a safe-
ty stop 1.
If an enabling switch malfunctions (e.g. jams in the central position), the indus-
trial robot can be stopped using the following methods:
 Press the enabling switch down fully.

5 Safety
 Actuate the EMERGENCY STOP device.

 Release the Start key.
The enabling switches must not be held down by adhe-

sive tape or other means or tampered with in any other
way.
Death, injuries or damage to property may result.
5.5.9 External enabling device
External enabling devices are required if it is necessary for more than one per-
son to be in the danger zone of the industrial robot.
External enabling devices are not included in the scope of supply of the indus-
trial robot.
Which interface can be used for connecting external enabling devices

is described in the “Planning” chapter of the robot controller operating
instructions and assembly instructions.
5.5.10 External safe operational stop
The safe operational stop can be triggered via an input on the customer inter-
face. The state is maintained as long as the external signal is FALSE. If the
external signal is TRUE, the manipulator can be moved again. No acknowl-
edgement is required.
5.5.11 External safety stop 1 and external safety stop 2
Safety stop 1 and safety stop 2 can be triggered via an input on the customer
interface. The state is maintained as long as the external signal is FALSE. If
the external signal is TRUE, the manipulator can be moved again. No ac-
knowledgement is required.
If interface X11 is selected as the customer interface, only the signal Safety
stop 2 is available.
5.5.12 Velocity monitoring in T1
The velocity at the mounting flange is monitored in T1 mode. If the velocity ex-
ceeds 250 mm/s, a safety stop 0 is triggered.
5.6 Additional protective equipment
5.6.1 Jog mode
In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High

Velocity), the robot controller can only execute programs in jog mode. This
means that it is necessary to hold down an enabling switch and the Start key
in order to execute a program.
 Releasing the enabling switch triggers a safety stop 2.
 Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
 Releasing the Start key triggers a STOP 2.

KR C4; KR C4 CK
5.6.2 Software limit switches
The axis ranges of all manipulator and positioner axes are limited by means of
adjustable software limit switches. These software limit switches only serve as
machine protection and must be adjusted in such a way that the manipula-
tor/positioner cannot hit the mechanical end stops.
The software limit switches are set during commissioning of an industrial ro-
bot.
Further information is contained in the operating and programming in-

structions.
5.6.3 Mechanical end stops
Depending on the robot variant, the axis ranges of the main and wrist axes of
the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.
If the manipulator or an external axis hits an obstruction

or a mechanical end stop or mechanical axis limitation,
the manipulator can no longer be operated safely. The manipulator must be
taken out of operation and KUKA Roboter GmbH must be consulted before
it is put back into operation .
5.6.4 Mechanical axis limitation (optional)
Some manipulators can be fitted with mechanical axis limitation systems in

axes A1 to A3. The axis limitation systems restrict the working range to the re-
quired minimum. This increases personal safety and protection of the system.
In the case of manipulators that are not designed to be fitted with mechanical
axis limitation, the workspace must be laid out in such a way that there is no
danger to persons or material property, even in the absence of mechanical
axis limitation.
If this is not possible, the workspace must be limited by means of photoelectric
barriers, photoelectric curtains or obstacles on the system side. There must be
no shearing or crushing hazards at the loading and transfer areas.
This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Roboter GmbH.
5.6.5 Axis range monitoring (optional)
Some manipulators can be fitted with dual-channel axis range monitoring sys-
tems in main axes A1 to A3. The positioner axes may be fitted with additional
axis range monitoring systems. The safety zone for an axis can be adjusted
and monitored using an axis range monitoring system. This increases person-
al safety and protection of the system.
This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Roboter GmbH.

5 Safety
5.6.6 Options for moving the manipulator without drive energy
The system user is responsible for ensuring that the training of per-
sonnel with regard to the response to emergencies or exceptional sit-
uations also includes how the manipulator can be moved without
drive energy.
Description The following options are available for moving the manipulator without drive
energy after an accident or malfunction:
 Release device (optional)
The release device can be used for the main axis drive motors and, de-
pending on the robot variant, also for the wrist axis drive motors.
 Brake release device (option)
The brake release device is designed for robot variants whose motors are
not freely accessible.
 Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in the low
payload category. This is not necessary because the wrist axes can be
moved directly by hand.
Information about the options available for the various robot models
and about how to use them can be found in the assembly and oper-
ating instructions for the robot or requested from KUKA Roboter
GmbH.
Moving the manipulator without drive energy can dam-

age the motor brakes of the axes concerned. The motor
must be replaced if the brake has been damaged. The manipulator may
therefore be moved without drive energy only in emergencies, e.g. for rescu-
ing persons.
5.6.7 Labeling on the industrial robot
All plates, labels, symbols and marks constitute safety-relevant parts of the in-
dustrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
 Identification plates
 Warning signs
 Safety symbols
 Designation labels
 Cable markings
 Rating plates
Further information is contained in the technical data of the operating

instructions or assembly instructions of the components of the indus-
trial robot.
5.6.8 External safeguards
The access of persons to the danger zone of the industrial robot must be pre-
vented by means of safeguards. It is the responsibility of the system integrator
to ensure this.

KR C4; KR C4 CK
Physical safeguards must meet the following requirements:

 They meet the requirements of EN ISO 14120.
 They prevent access of persons to the danger zone and cannot be easily
circumvented.
 They are sufficiently fastened and can withstand all forces that are likely
to occur in the course of operation, whether from inside or outside the en-
closure.
 They do not, themselves, represent a hazard or potential hazard.
 The prescribed minimum clearance from the danger zone is maintained.
Safety gates (maintenance gates) must meet the following requirements:
 They are reduced to an absolute minimum.
 The interlocks (e.g. safety gate switches) are linked to the operator safety
input of the robot controller via safety gate switching devices or safety
PLC.
 Switching devices, switches and the type of switching conform to the re-
quirements of Performance Level d and category 3 according to
EN ISO 13849-1.
 Depending on the risk situation: the safety gate is additionally safeguarded
by means of a locking mechanism that only allows the gate to be opened
if the manipulator is safely at a standstill.
 The button for acknowledging the safety gate is located outside the space
limited by the safeguards.
Further information is contained in the corresponding standards and

regulations. These also include EN ISO 14120.
Other safety Other safety equipment must be integrated into the system in accordance with
equipment the corresponding standards and regulations.
5.7 Overview of operating modes and safety functions
The following table indicates the operating modes in which the safety functions
are active.
Safety functions T1 T2 AUT AUT EXT

Operator safety - - Active Active
EMERGENCY STOP device Active Active Active Active
Enabling device Active Active - -
Reduced velocity during pro-
Active - - -
gram verification
Jog mode Active Active - -
Software limit switches Active Active Active Active
5.8 Safety measures
5.8.1 General safety measures
The industrial robot may only be used in perfect technical condition in accor-
dance with its intended use and only by safety-conscious persons. Operator
errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial robot
even after the robot controller has been switched off and locked out. Incorrect

5 Safety
installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause
the manipulator or external axes to sag. If work is to be carried out on a
switched-off industrial robot, the manipulator and external axes must first be
moved into a position in which they are unable to move on their own, whether
the payload is mounted or not. If this is not possible, the manipulator and ex-
ternal axes must be secured by appropriate means.
In the absence of operational safety functions and safe-

guards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deacti-
vated, the industrial robot may not be operated.
Standing underneath the robot arm can cause death or

injuries. For this reason, standing underneath the robot
arm is prohibited!
The motors reach temperatures during operation which

can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.
smartPAD The user must ensure that the industrial robot is only operated with the smart-
PAD by authorized persons.
If more than one smartPAD is used in the overall system, it must be ensured
that each smartPAD is unambiguously assigned to the corresponding indus-
trial robot. They must not be interchanged.
The operator must ensure that decoupled smartPADs

are immediately removed from the system and stored out
of sight and reach of personnel working on the industrial robot. This serves
to prevent operational and non-operational EMERGENCY STOP devices
from becoming interchanged.
Failure to observe this precaution may result in death, severe injuries or con-
siderable damage to property.
Modifications After modifications to the industrial robot, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety functions
must also be tested.
New or modified programs must always be tested first in Manual Reduced Ve-
locity mode (T1).
After modifications to the industrial robot, existing programs must always be
tested first in Manual Reduced Velocity mode (T1). This applies to all compo-
nents of the industrial robot and includes modifications to the software and
configuration settings.
Faults The following tasks must be carried out in the case of faults in the industrial
robot:
 Switch off the robot controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
 Indicate the fault by means of a label with a corresponding warning (tag-
out).
 Keep a record of the faults.
 Eliminate the fault and carry out a function test.

KR C4; KR C4 CK
5.8.2 Transportation
Manipulator The prescribed transport position of the manipulator must be observed. Trans-
portation must be carried out in accordance with the operating instructions or
assembly instructions of the robot.
Avoid vibrations and impacts during transportation in order to prevent damage
to the manipulator.
Robot controller The prescribed transport position of the robot controller must be observed.
Transportation must be carried out in accordance with the operating instruc-
tions or assembly instructions of the robot controller.
Avoid vibrations and impacts during transportation in order to prevent damage
to the robot controller.
External axis The prescribed transport position of the external axis (e.g. KUKA linear unit,
(optional) turn-tilt table, positioner) must be observed. Transportation must be carried
out in accordance with the operating instructions or assembly instructions of
the external axis.
5.8.3 Start-up and recommissioning
Before starting up systems and devices for the first time, a check must be car-
ried out to ensure that the systems and devices are complete and operational,
that they can be operated safely and that any damage is detected.
The valid national or regional work safety regulations must be observed for this
check. The correct functioning of all safety functions must also be tested.
The passwords for the user groups must be changed in the KUKA
System Software before start-up. The passwords must only be com-
municated to authorized personnel.
The robot controller is preconfigured for the specific in-

dustrial robot. If cables are interchanged, the manipula-
tor and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.
If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Roboter GmbH, are integrated into the industrial
robot, the user is responsible for ensuring that these components do
not adversely affect or disable safety functions.
If the internal cabinet temperature of the robot controller

differs greatly from the ambient temperature, condensa-
tion can form, which may cause damage to the electrical components. Do not
put the robot controller into operation until the internal temperature of the
cabinet has adjusted to the ambient temperature.
Function test The following tests must be carried out before start-up and recommissioning:
General test:
It must be ensured that:
 The industrial robot is correctly installed and fastened in accordance with
the specifications in the documentation.

5 Safety
 There is no damage to the robot that could be attributed to external forces.

Examples: Dents or abrasion that could be caused by an impact or colli-
sion.
In the case of such damage, the affected components

must be exchanged. In particular, the motor and counter-
balancing system must be checked carefully.
External forces can cause non-visible damage. For example, it can lead to
a gradual loss of drive power from the motor, resulting in unintended move-
ments of the manipulator. Death, injuries or considerable damage to property
may otherwise result.
 There are no foreign bodies or loose parts on the industrial robot.

 All required safety equipment is correctly installed and operational.
 The power supply ratings of the industrial robot correspond to the local
supply voltage and mains type.
 The ground conductor and the equipotential bonding cable are sufficiently
rated and correctly connected.
 The connecting cables are correctly connected and the connectors are
locked.
Test of the safety functions:
A function test must be carried out for the following safety functions to ensure
that they are functioning correctly:
 Local EMERGENCY STOP device
 External EMERGENCY STOP device (input and output)
 Enabling device (in the test modes)
 Operator safety
 All other safety-relevant inputs and outputs used
 Other external safety functions
5.8.3.1 Checking machine data and safety configuration
The industrial robot must not be moved if incorrect ma-

chine data or an incorrect controller configuration are
loaded. Death, severe injuries or considerable damage to property may oth-
erwise result. The correct data must be loaded.
 The practical tests for the machine data must be carried out within the
scope of the start-up procedure.
 Following modifications to the machine data, the safety configuration must
be checked.
 After activation of a WorkVisual project on the robot controller, the safety
configuration must be checked!
 If machine data are adopted when checking the safety configuration (re-
gardless of the reason for the safety configuration check), the practical
tests for the machine data must be carried out.
 System Software 8.3 or higher: If the checksum of the safety configuration
has changed, the safe axis monitoring functions must be checked.
Information about checking the safety configuration and the safe axis
monitoring functions is contained in the Operating and Programming
Instructions for System Integrators.
If the practical tests are not successfully completed in the initial start-up, KUKA
Roboter GmbH must be contacted.

KR C4; KR C4 CK
If the practical tests are not successfully completed during a different proce-
dure, the machine data and the safety-relevant controller configuration must
be checked and corrected.
General practical test:
If practical tests are required for the machine data, this test must always be
carried out.
The following methods are available for performing the practical test:
 TCP calibration with the XYZ 4-point method
The practical test is passed if the TCP has been successfully calibrated.
or:
1. Align the TCP with a freely selected point.
The point serves as a reference point. It must be located so that reorien-
tation is possible.
2. Move the TCP manually at least 45° once in each of the A, B and C direc-
tions.
The movements do not have to be accumulative, i.e. after motion in one
direction it is possible to return to the original position before moving in the
next direction.
The practical test is passed if the TCP does not deviate from the reference
point by more than 2 cm in total.
Practical test for axes that are not mathematically coupled:
If practical tests are required for the machine data, this test must be carried out
when axes are present that are not mathematically coupled.
1. Mark the starting position of the axis that is not mathematically coupled.
2. Move the axis manually by a freely selected path length. Determine the
path length from the display Actual position on the smartHMI.
 Move linear axes a specific distance.
 Move rotational axes through a specific angle.
3. Measure the length of the path covered and compare it with the value dis-
played on the smartHMI.
The practical test is passed if the values differ by no more than 10%.
4. Repeat the test for each axis that is not mathematically coupled.
Practical test for couplable axes:
If practical tests are required for the machine data, this test must be carried out
when axes are present that can be physically coupled and uncoupled, e.g. a
servo gun.
1. Physically uncouple the couplable axis.
2. Move all the remaining axes individually.
The practical test is passed if it has been possible to move all the remain-
ing axes.
5.8.3.2 Start-up mode
Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 without the external
safeguards being put into operation.
When Start-up mode is possible depends on the safety interface that is used.
Discrete safety interface

5 Safety
 System Software 8.2 or earlier:

Start-up mode is always possible if all input signals at the discrete safety
interface have the state “logic zero”. If this is not the case, the robot con-
troller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the in-
puts there must also have the state “logic zero”.
 System Software 8.3 or higher:
Start-up mode is always possible. This also means that it is independent
of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection to a
higher-level safety system exists or is established.
Effect When the Start-up mode is activated, all outputs are automatically set to the
state “logic zero”.
If the robot controller has a peripheral contactor (US2), and if the safety con-
figuration specifies for this to switch in accordance with the motion enable,
then the same also applies in Start-up mode. This means that if motion enable
is present, the US2 voltage is switched on – even in Start-up mode.
Hazards Possible hazards and risks involved in using Start-up mode:

 A person walks into the manipulator’s danger zone.
 In a hazardous situation, a disabled external EMERGENCY STOP device
is actuated and the manipulator is not shut down.
Additional measures for avoiding risks in Start-up mode:
 Cover disabled EMERGENCY STOP devices or attach a warning sign in-
dicating that the EMERGENCY STOP device is out of operation.
 If there is no safety fence, other measures must be taken to prevent per-
sons from entering the manipulator’s danger zone, e.g. use of warning
tape.
Use Intended use of Start-up mode:

 Start-up in T1 mode when the external safeguards have not yet been in-
stalled or put into operation. The danger zone must be delimited at least
by means of warning tape.
 Fault localization (periphery fault).
 Use of Start-up mode must be minimized as much as possible.
Use of Start-up mode disables all external safeguards.

The service personnel are responsible for ensuring that
there is no-one in or near the danger zone of the manipulator as long as the
safeguards are disabled.
Failure to observe this precaution may result in death, injuries or damage to
property.
and is not allowed. KUKA Roboter GmbH is not liable for any damage resulting
from such misuse. The risk lies entirely with the user.

KR C4; KR C4 CK
5.8.4 Manual mode
Manual mode is the mode for setup work. Setup work is all the tasks that have
to be carried out on the industrial robot to enable automatic operation. Setup
work includes:
 Jog mode
 Teaching
 Programming
 Program verification
The following must be taken into consideration in manual mode:
 New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).
 The manipulator, tooling or external axes (optional) must never touch or
project beyond the safety fence.
 Workpieces, tooling and other objects must not become jammed as a re-
sult of the industrial robot motion, nor must they lead to short-circuits or be
liable to fall off.
 All setup work must be carried out, where possible, from outside the safe-
guarded area.
If the setup work has to be carried out inside the safeguarded area, the follow-
ing must be taken into consideration:
In Manual Reduced Velocity mode (T1):
 If it can be avoided, there must be no other persons inside the safeguard-
ed area.
If it is necessary for there to be several persons inside the safeguarded ar-
ea, the following must be observed:
 Each person must have an enabling device.
 All persons must have an unimpeded view of the industrial robot.
 Eye-contact between all persons must be possible at all times.
 The operator must be so positioned that he can see into the danger area
and get out of harm’s way.
In Manual High Velocity mode (T2):
 This mode may only be used if the application requires a test at a velocity
higher than that possible in T1 mode.
 Teaching and programming are not permissible in this operating mode.
 Before commencing the test, the operator must ensure that the enabling
devices are operational.
 The operator must be positioned outside the danger zone.
 There must be no other persons inside the safeguarded area. It is the re-
sponsibility of the operator to ensure this.
5.8.5 Simulation
Simulation programs do not correspond exactly to reality. Robot programs cre-

ated in simulation programs must be tested in the system in Manual Reduced
Velocity mode (T1). It may be necessary to modify the program.

5 Safety
5.8.6 Automatic mode
Automatic mode is only permissible in compliance with the following safety

measures:
 All safety equipment and safeguards are present and operational.
 There are no persons in the system.
 The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for no ap-
parent reason, the danger zone must not be entered until an EMERGENCY
STOP has been triggered.
5.8.7 Maintenance and repair
After maintenance and repair work, checks must be carried out to ensure the
required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety functions
must also be tested.
The purpose of maintenance and repair work is to ensure that the system is
kept operational or, in the event of a fault, to return the system to an operation-
al state. Repair work includes troubleshooting in addition to the actual repair
itself.
The following safety measures must be carried out when working on the indus-
trial robot:
 Carry out work outside the danger zone. If work inside the danger zone is
necessary, the user must define additional safety measures to ensure the
safe protection of personnel.
 Switch off the industrial robot and secure it (e.g. with a padlock) to prevent
it from being switched on again. If it is necessary to carry out work with the
robot controller switched on, the user must define additional safety mea-
sures to ensure the safe protection of personnel.
 If it is necessary to carry out work with the robot controller switched on, this
may only be done in operating mode T1.
 Label the system with a sign indicating that work is in progress. This sign
must remain in place, even during temporary interruptions to the work.
 The EMERGENCY STOP devices must remain active. If safety functions
or safeguards are deactivated during maintenance or repair work, they
must be reactivated immediately after the work is completed.
Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again. The system must then be checked to en-
sure that it is deenergized.
It is not sufficient, before commencing work on live parts, to execute an
EMERGENCY STOP or a safety stop, or to switch off the drives, as this does
not disconnect the robot system from the mains power supply. Parts remain
energized. Death or severe injuries may result.
Faulty components must be replaced using new components with the same
article numbers or equivalent components approved by KUKA Roboter GmbH
for this purpose.
Cleaning and preventive maintenance work is to be carried out in accordance
with the operating instructions.
Robot controller Even when the robot controller is switched off, parts connected to peripheral
devices may still carry voltage. The external power sources must therefore be
switched off if work is to be carried out on the robot controller.

KR C4; KR C4 CK
The ESD regulations must be adhered to when working on components in the

robot controller.
Voltages in excess of 50 V (up to 780 V) can be present in various components
for several minutes after the robot controller has been switched off! To prevent
life-threatening injuries, no work may be carried out on the industrial robot in
this time.
Water and dust must be prevented from entering the robot controller.
Counterbal- Some robot variants are equipped with a hydropneumatic, spring or gas cylin-
ancing system der counterbalancing system.
The hydropneumatic and gas cylinder counterbalancing systems are pressure
equipment and, as such, are subject to obligatory equipment monitoring and
the provisions of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and stan-
dards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order,
Sections 14 and 15. Inspection by the user before commissioning at the instal-
lation site.
The following safety measures must be carried out when working on the coun-
terbalancing system:
 The manipulator assemblies supported by the counterbalancing systems
must be secured.
 Work on the counterbalancing systems must only be carried out by quali-
fied personnel.
Hazardous The following safety measures must be carried out when handling hazardous
substances substances:
 Avoid prolonged and repeated intensive contact with the skin.
 Avoid breathing in oil spray or vapors.
 Clean skin and apply skin cream.
To ensure safe use of our products, we recommend regularly re-

questing up-to-date safety data sheets for hazardous substances.
5.8.8 Decommissioning, storage and disposal
The industrial robot must be decommissioned, stored and disposed of in ac-

cordance with the applicable national laws, regulations and standards.
5.8.9 Safety measures for “single point of control”
Overview If certain components in the industrial robot are operated, safety measures
must be taken to ensure complete implementation of the principle of “single
point of control” (SPOC).
The relevant components are:
 Submit interpreter
 PLC
 OPC server
 Remote control tools
 Tools for configuration of bus systems with online functionality
 KUKA.RobotSensorInterface

5 Safety
The implementation of additional safety measures may be required.

This must be clarified for each specific application; this is the respon-
sibility of the system integrator, programmer or user of the system.
Since only the system integrator knows the safe states of actuators in the pe-
riphery of the robot controller, it is his task to set these actuators to a safe
state, e.g. in the event of an EMERGENCY STOP.
T1, T2 In modes T1 and T2, the components referred to above may only access the
industrial robot if the following signals have the following states:
Signal State required for SPOC

$USER_SAF TRUE
$SPOC_MOTION_ENABLE TRUE
Submit inter- If motions, (e.g. drives or grippers) are controlled with the submit interpreter or
preter, PLC the PLC via the I/O system, and if they are not safeguarded by other means,
then this control will take effect even in T1 and T2 modes or while an EMER-
GENCY STOP is active.
If variables that affect the robot motion (e.g. override) are modified with the
submit interpreter or the PLC, this takes effect even in T1 and T2 modes or
while an EMERGENCY STOP is active.
Safety measures:
 In T1 and T2, the system variable $OV_PRO must not be written to by the
submit interpreter or the PLC.
 Do not modify safety-relevant signals and variables (e.g. operating mode,
EMERGENCY STOP, safety gate contact) via the submit interpreter or
PLC.
If modifications are nonetheless required, all safety-relevant signals and
variables must be linked in such a way that they cannot be set to a dan-
gerous state by the submit interpreter or PLC. This is the responsibility of
the system integrator.
OPC server, These components can be used with write access to modify programs, outputs
remote control or other parameters of the robot controller, without this being noticed by any
tools persons located inside the system.
Safety measure:
If these components are used, outputs that could cause a hazard must be de-
termined in a risk assessment. These outputs must be designed in such a way
that they cannot be set without being enabled. This can be done using an ex-
ternal enabling device, for example.
Tools for configu- If these components have an online functionality, they can be used with write
ration of bus access to modify programs, outputs or other parameters of the robot control-
systems ler, without this being noticed by any persons located inside the system.
 WorkVisual from KUKA
 Tools from other manufacturers
Safety measure:
In the test modes, programs, outputs or other parameters of the robot control-
ler must not be modified using these components.
5.9 Applied norms and regulations
Name Definition Edition

KR C4; KR C4 CK
2006/42/EC Machinery Directive: 2006

Directive 2006/42/EC of the European Parliament and of the
Council of 17 May 2006 on machinery, and amending Direc-
tive 95/16/EC (recast)
2014/30/EU EMC Directive: 2014

Directive 2014/30/EC of the European Parliament and of the
Council of 26 February 2014 on the approximation of the laws
of the Member States concerning electromagnetic compatibil-
ity
2014/68/EU Pressure Equipment Directive: 2014

Directive 2014/68/EU of the European Parliament and of the
Council of 15 May 2014 on the approximation of the laws of
the Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbal-
ancing system.)
EN ISO 13850 Safety of machinery: 2015

Emergency stop - Principles for design
EN ISO 13849-1 Safety of machinery: 2015

Safety-related parts of control systems - Part 1: General prin-
ciples of design
EN ISO 13849-2 Safety of machinery: 2012

Safety-related parts of control systems - Part 2: Validation
EN ISO 12100 Safety of machinery: 2010

General principles of design, risk assessment and risk reduc-
tion
EN ISO 10218-1 Industrial robots – Safety requirements 2011

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1
EN 614-1 + A1 Safety of machinery: 2009

Ergonomic design principles - Part 1: Terms and general prin-
ciples
EN 61000-6-2 Electromagnetic compatibility (EMC): 2005

Part 6-2: Generic standards; Immunity for industrial environ-
ments
EN 61000-6-4 + A1 Electromagnetic compatibility (EMC): 2011

Part 6-4: Generic standards; Emission standard for industrial
environments

5 Safety
EN 60204-1 + A1 Safety of machinery: 2009

Electrical equipment of machines - Part 1: General require-
ments

KR C4; KR C4 CK

6 Planning
6 Planning
Overview Step Description Information
1 Electromagnetic compati- (>>> 6.1 "Electromagnetic com-
bility (EMC) patibility (EMC)" Page 69)
2 Installation conditions for (>>> 6.2 "Installation condi-
robot controller tions" Page 69)
3 Connection conditions (>>> 6.3 "Connection condi-
tions" Page 70)
4 Installation of the KUKA (>>> 4.6 "Dimensions of the
smartPAD holder smartPAD holder (optional)"
(optional) Page 38)
5 Interfaces (>>> 6.5 "Overview of inter-
faces" Page 72)
6 Power supply connection (>>> 6.7 "Power supply connec-
tion via X1 Harting connector"
Page 91)
7 Safety interface X11 (>>> 6.8.1.2 "Safety interface
X11" Page 92)
8 Ethernet safety interface (>>> 6.9.1 "Safety functions via
X66 Ethernet safety interface"
Page 99)
9 EtherCAT connection on (>>> 6.10 "EtherCAT connec-
the CIB tion on the CIB" Page 108)
10 PE equipotential bonding (>>> 6.11 "PE equipotential
bonding" Page 108)
11 Modification of the system (>>> 6.12 "Modifying the sys-
structure, exchange of tem configuration, exchanging
devices devices" Page 110)
12 Acknowledgment of opera- (>>> 6.13 "Operator safety
tor safety acknowledgement" Page 110)
13 Performance level (>>> 6.14 "Performance level"
Page 110)
6.1 Electromagnetic compatibility (EMC)
Description If connecting cables (e.g. field buses, etc.) are routed to the control PC from
outside, only shielded cables with an adequate degree of shielding may be
used. The cable shield must be connected with maximum surface area to the
PE rail in the cabinet using shield terminals (screw-type, no clamps).
The robot controller corresponds to EMC class A, Group 1, in accor-

dance with EN 55011 and is intended for use in an industrial setting.
Assuring the electromagnetic compatibility in other environments
may be difficult due to conducted and radiated disturbances that are liable to
occur.
6.2 Installation conditions
The dimensions and installation conditions of the robot controller are specified
in the section “Technical data”.
(>>> 4.3 "Dimensions of robot controller" Page 36)
(>>> 4.4 "Minimum clearances, robot controller" Page 37)

KR C4; KR C4 CK
(>>> 4.5 "Swing range for cabinet door" Page 38)
Robot controller One robot controller can be stacked on top of another one. The upper robot
stacked controller, with standard cabinet base only, must be firmly screwed to the low-
er one. To do so, the 4 threads of the eyebolts must be used. The lower robot
controller must not be mounted on rollers and must be fastened to the floor.
A stacked robot controller is illustrated in the diagram (>>> Fig. 6-1 ).
Fig. 6-1: Stacked robot controller
6.3 Connection conditions
Power supply
connection without a grounded neutral or is operated with incorrect
machine data, this may cause malfunctions in the robot controller and mate-
rial damage to the power supply units. Electrical voltage can cause injuries.
The robot controller may only be operated with grounded-neutral power sup-
ply systems.
If no grounded neutral is available, or if the mains voltage differs from those

specified here, a transformer must be used.
Rated supply voltage according to AC 3x380 V, AC 3x400 V,

the machine data, optionally: AC 3x440 V or AC 3x480 V
Permissible tolerance of rated sup- Rated supply voltage ±10%
ply voltage
Mains frequency 49 … 61 Hz
System impedance up to the con- ≤ 300 mΩ
nection point of the robot controller
Ground leakage current up to 300 mA
Full-load current See rating plate
Mains-side fusing without trans- min. 3x25 A, slow-blowing
former

6 Planning
Mains-side fusing with transformer min. 3x32 A, slow-blowing, with

13 kVA
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.
If the robot controller is operated with a supply voltage

other than that specified on the rating plate, this may
cause malfunctions in the robot controller and material damage to the power
supply units. The robot controller may only be operated with the supply volt-
age specified on the rating plate.
The appropriate machine data must be loaded in accordance with the

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

be borne in mind that a residual current of up to 300 mA can be ex-
pected in faultless operation. An RCCB of this rating serves the pur-
pose of equipment protection but not of personnel protection. We
recommend the following RCCB: universal-current sensitive, selective.
Cable lengths For cable designations, standard lengths and optional lengths, please refer to
the operating instructions or assembly instructions of the manipulator and/or
the assembly and operating instructions for KR C4 external cabling for robot
controllers.
When using smartPAD cable extensions, only two extensions may be

used. An overall cable length of 50 m must not be exceeded.
The difference in the cable lengths between the individual channels

of the RDC box must not exceed 10 m.
PELV external External voltage PELV power supply unit acc. to EN

power supply 60950 with rated voltage 27 V (18 V
... 30 V), safely isolated
Continuous current >8A
Cable cross-section of power sup- ≥ 1 mm2
ply cable
Cable length of power supply cable < 50 m, or < 100 m wire length (out-
The cables of the power supply unit must not be routed together with
power-carrying cables.
The minus connection of the external voltage must be grounded by

the customer.
Parallel connection of a basic-insulated device is not permitted.

KR C4; KR C4 CK
6.4 Fastening the KUKA smartPAD holder (optional)
Overview The smartPAD holder can be installed on the door of the robot controller or on
the safety fence.
The following diagram (>>> Fig. 6-2 ) shows the options for fastening the
smartPAD holder.
Fig. 6-2: smartPAD holder
1 M6x12 Allen screw 3 Door of robot controller

2 Spring lock washer A6.1 and 4 Iron flat for fence mounting
plain washer
6.5 Overview of interfaces
The robot controller variant KR C4 NA comprises the following interfaces:

 Motor connector 1
 Motor connector X20
 Motor connector X20, KPP and KSP
 Motor connectors X20.1 and X20.4 (heavy-duty robot)
 Motor connector X7.1, external axis 1
 Motor connectors X7.1 and X7.2, external axes 1 and 2
 Motor connectors X7.1, X7.2 and X7.3, external axes 1, 2 and 3
 Motor connector X8 (heavy-duty palletizing robot, 4 axes)
 Motor connector X20 (palletizing robot, 4 axes)
 Motor connectors X20.1 and X20.4 (heavy-duty robot, 5 axes)
 Motor connector X20 (palletizing robot, 5 axes)
 Motor connector X81 (4 axes)
 Motor connector X7.1, external axis 1 (palletizing robot)
 Motor connectors X7.1 and X7.2, external axes 1 and 2 (palletizing ro-
bot)

6 Planning

 Motor connectors X81 and X7.1 (5 axes)
 Motor connectors X81, X7.1 and X7.2 (6 axes)
 Motor connectors X81, X7.1...X7.3 (7 axes)
 Motor connectors X81, X7.1...X7.4 (8 axes)
 Motor connectors X7.1...X7.3 (3 axes)
 Power supply connection X1
 Discrete interfaces for safety options
 X11 parallel safety
 Ethernet interfaces
 Ethernet safety interface X66
Connection panel
Fig. 6-3: Connection panel overview
1 X1 Power supply connection

2 Motor connector interfaces
3 Option
4 Option
5 X11 Safety interface
6 Option
7 Option
8 X19 smartPAD connection
9 X42 optional
10 X21 RDC connection
11 X66 Ethernet safety interface
12 PE1 Ground conductor to manipulator
13 PE2 Ground conductor to main infeed
Only safety interface X11 or Ethernet safety interface X66 (PRO-

FIsafe/CIP Safety) can be configured.

KR C4; KR C4 CK
The fundamental planning information for the robot controller can be

found in the “Planning” chapter of the operating instructions for the ro-
bot controller.
6.6 Motor interfaces
Description The motors and brakes of the robot controller or the external axes are connect-
ed to the robot controller via the following motor connectors. Two possible con-
nector inserts for an individual axis are shown below. The connector inserts
can be combined to multiple connectors.
The following sections show the internal cabling as well as the combinations
of connector inserts that are possible to multiple connectors.
Necessary  Cable 3X AWG8

equipment  Cable 2X AWG18
 Harting connector, HAN Modular
Fig. 6-4: Connector contact diagram, connector side
Connector pin
Pin Description
allocation
1 Motor U1
2 Motor V1
3 Motor W1
11 Brake 24 V
12 Brake 0 V
Necessary  Cable 3X AWG12

equipment  Cable 2X AWG18
 Harting connector, HAN E Modular
Fig. 6-5: Connector contact diagram, connector side
Connector pin Pin Description

allocation
1 Motor U1
2 Not assigned
3 Brake 24 V
4 Motor V1

6 Planning
Pin Description
5 Brake 0 V
6 Motor W1
In the circuit diagram, the letter for the relevant connecter insert is placed in
front of the pin numbers.
6.6.1 Motor connector Xxx, external axes X7.1, X7.2, X7.3
Connection panel
Fig. 6-6: Connection panel
1 Slot 1 (>>> "Assignment of slot 1" Page 75)

2 Slot 2 (>>> "Assignment of slot 2" Page 75)
3 X7.1 Motor connection, external axis 7
Assignment of Slot 1 can be assigned the following motor connections:

slot 1  X20.1 Motor connector, heavy-duty robot, axes 1-3
Assignment of Slot 2 can be assigned the following motor connections:

slot 2  X20 Motor connector, axes 1 to 6
 X20.4 Motor connector, heavy-duty robot, axes 4-6
Designations These designations are used in the following wiring diagrams:
Mx Motor x
Br Mx Brake, motor x

KR C4; KR C4 CK
6.6.1.1 Motor connector X20
Fig. 6-7: Connector inserts
Motor connector
Connec-
X20 Axis Axis servo Connection
tor insert
A1 A KSP T2 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KSP T1 X1/X31
A5 E X2/X32
A6 F X3/X33
Motor connector
Connec-
X20 for 3 external Axis Axis servo Connection
tor insert
axes
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KPP G1 X1/X31
A5 E X2/X32
A6 F X3/X33
6.6.1.2 Motor connector X20, KPP and KSP

6 Planning
Motor connector
Connec-
X20 Axis Axis servos Connection
tor insert
A1 A KSP T2 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KSP T1 X1/X31
A5 E X2/X32
A6 F X3/X33
6.6.1.3 Motor connectors X20.1 and X20.4 (heavy-duty robot)
Motor connector Connec-

X20.1 Axis Axis servos Connection
tor insert
A1 A KSP T2 X1/X31
A2 B X2/X32
A3 C X3/X33

tor insert
A4 A KSP T1 X1/X31
A5 B X2/X32
A6 C X3/X33
6.6.1.4 Motor connector X7.1, external axis 1
The motor cable must not exceed a total length of 50 m.

KR C4; KR C4 CK
Motor connector
Connec-
tor insert
A7 A KPP G1 X2/X32
6.6.1.5 Motor connectors X7.1 and X7.2, external axes 1 and 2
The motor cable must not exceed a total length of 50 m.

X7.1 Axis Axis servo Connection
tor insert
A7 A KPP G1 X2/X32
Motor connector
Connec-
tor insert
A8 A KPP G1 X3/X33
6.6.1.6 X7.1, X7.2, X7.3, motor connectors, external axes 1, 2, 3
Motor connector
Connec-
tor insert
A7 A KSP T2 or KPP G1 X1/X31

tor insert
A8 B KSP T2 or KPP G1 X2/X32
Motor connector
Connec-
tor insert
A9 C KSP T2 or KPP G1 X3/X33

6 Planning
6.6.1.7 Motor connector X8 (heavy-palletizing duty robot, 4 axes)
Motor connector
Connec-
X8, 4 axes Axis Axis servo Connection
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
A6 D KPP G1 X2/X32
6.6.1.8 Motor connector X20 (palletizing robot, 4 axes)
Motor connector
Connec-
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
A6 F KPP G1 X2/X32

KR C4; KR C4 CK
6.6.1.9 Motor connectors X20.1 and X20.4 (heavy-duty robot, 5 axes)
Motor connector
Connec-
X20.1, 5 axes Axis Axis servo Connection
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
Motor connector
Connec-
X20.4, 5 axes Axis Axis servo Connection
tor insert
A5 B KPP G1 X2/X32
A6 C X3/X33
6.6.1.10 Motor connector X20 (palletizing robot, 5 axes)
Motor connector
Connec-
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 E KPP G1 X2/X32
A5 F X3/X33

6 Planning
6.6.1.11 Motor connector X81 (4 axes)
Motor connector
Connec-
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KPP G1 X2/X32
Motor connector
Connec-
tor insert
A5 A KSP T2 X1/X31
A6 B X2/X32
A7 C X3/X33
A8 D KPP G1 X3/X33

KR C4; KR C4 CK
6.6.1.13 Motor connector X7.1, external axis 1 (palletizing robot)
Motor connector
Connec-
tor insert
A1 A KSP T2 X1/X31
6.6.1.14 Connector pin allocation for motor connectors X7.1 and X7.2, external axes 1 and 2
(palletizing robot)

tor insert
A1 A KSP T2 X1/X31

tor insert
A2 A KSP T2 X2/X32
6.6.2 Multiple connector X81, single connectors X7.1 to X7.4
Connection panel
Fig. 6-21: Connection panel with X81 and X7.1 to X7.4
1 Multiple connector X81 for axes 1 to 4

2 Single connector X7.1 for axis 5

6 Planning

Mx Motor x
Motor connector
Connec-
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
Motor connector
Connec-
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KPP G1 X2/X32

KR C4; KR C4 CK
6.6.2.3 Motor connectors X81 and X7.1 (5 axes)
Motor connector
Connec-
X81, Axis Axis servo Connection
tor insert
A1 A KSP T1 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KPP G1 X2/X32
Motor connector
Connec-
tor insert
A5 A KPP G1 X3/X33
6.6.2.4 Motor connectors X81, X7.1 and X7.2 (6 axes)

6 Planning
Motor connector
Connec-
tor insert
A1 A KSP T2 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KSP T1 X1/X31

tor insert
A5 A KSP T1 X2/X32

tor insert
A6 A KSP T1 X3/X33
6.6.2.5 Motor connectors X81, X7.1...X7.3 (7 axes)

tor insert
A1 A KSP T2 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KSP T1 X1/X31

KR C4; KR C4 CK
Motor connector
Connec-
tor insert
A5 A KSP T1 X2/X32

tor insert
A6 A KSP T1 X3/X33
Motor connector
Connec-
tor insert
A7 A KPP G1 X2/X32
6.6.2.6 Motor connectors X81, X7.1...X7.4 (8 axes)
Motor connector
Connec-
tor insert
A1 A KSP T2 X1/X31
A2 B X2/X32
A3 C X3/X33
A4 D KSP T1 X1/X31
Motor connector
Connec-
tor insert
A5 A KSP T1 X2/X32

tor insert
A6 A KSP T1 X3/X33

6 Planning
Motor connector
Connec-
tor insert
A7 A KPP G1 X2/X32

tor insert
A8 A KPP G1 X3/X33
6.6.3 Single connectors X7.1 to X7.8
Connector pin
allocation
Fig. 6-32: Connection panel with X7.1 to X7.8

Mx Motor x
6.6.3.1 Motor connectors X7.1...X7.3 (3 axes)
Motor connector
Connec-
tor insert
A1 A KSP T1 X1/X31

KR C4; KR C4 CK
Motor connector
Connec-
tor insert
A2 A KSP T1 X2/X32

tor insert
A3 A KSP T1 X3/X33

tor insert
A1 A KSP T1 X1/X31
Motor connector
Connec-
tor insert
A2 A KSP T1 X2/X32

tor insert
A3 A KSP T1 X3/X33

tor insert
A4 A KPP G1 X2/X32

tor insert
A1 A KSP T1 X1/X31
Motor connector
Connec-
tor insert
A2 A KSP T1 X2/X32

6 Planning
Motor connector
Connec-
tor insert
A3 A KSP T1 X3/X33

tor insert
A4 A KPP G1 X2/X32
Motor connector
Connec-
tor insert
A5 A KPP G1 X3/X33
Motor connector
Connec-
tor insert
A1 A KSP T2 X1/X31

tor insert
A2 A KSP T2 X2/X32

tor insert
A3 A KSP T2 X3/X33
Motor connector
Connec-
tor insert
A4 A KSP T1 X1/X31

tor insert
A5 A KSP T1 X2/X23

tor insert
A6 A KSP T1 X3/X33

KR C4; KR C4 CK
Motor connector
Connec-
tor insert
A1 A KSP T2 X1/X31

tor insert
A2 A KSP T2 X2/X32

tor insert
A3 A KSP T2 X3/X33
Motor connector
Connec-
tor insert
A4 A KSP T1 X1/X31

tor insert
A5 A KSP T1 X2/X23

tor insert
A6 A KSP T1 X3/X33
Motor connector
Connec-
tor insert
A7 A KPP G1 X2/X32
Motor connector
Connec-
tor insert
A1 A KSP T2 X1/X31

6 Planning
Motor connector
Connec-
tor insert
A2 A KSP T2 X2/X32

tor insert
A3 A KSP T2 X3/X33
Motor connector
Connec-
tor insert
A4 A KSP T1 X1/X31

tor insert
A5 A KSP T1 X2/X23

tor insert
A6 A KSP T1 X3/X33
Motor connector
Connec-
tor insert
A7 A KPP G1 X2/X32

tor insert
A8 A KPP G1 X3/X33
6.7 Power supply connection via X1 Harting connector
Description A Harting connector bypack is supplied with the robot controller. The customer
can connect the robot controller to the power supply via connector X1.
If the robot controller is connected to a rated supply voltage greater

than 400 V without a transformer, the power cable to X1 must be
shielded. The shield must be connected to ground on at least one
side.
Fig. 6-39: Power supply connection X1

KR C4; KR C4 CK
1 Harting connector bypack (optional)

2 Power supply connection X1
6.8 Discrete interfaces for safety options
6.8.1 Description of safety interface X11
Description EMERGENCY STOP devices must be connected via safety interface X11 or
linked together by means of higher-level controllers (e.g. PLC). (>>> "SIB
outputs" Page 35)
Wiring Take the following points into consideration when wiring safety interface X11:
 System concept
 Safety concept
6.8.1.1 X11 connector contact diagram
Contact diagram,
connector X11
Fig. 6-40: Contact diagram
 X11, mating connector: Han 108DD with a male insert

 Housing size: 24B
 Cable gland M32
 Cable diameter 14-21 mm
 Cable cross-section ≥ 1 mm2
In the cabling for the input signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the voltages (e.g. separate cabling of input signals and test signals).
In the cabling for the output signals and test signals in the system,
suitable measures must be taken to prevent a cross-connection be-
tween the output signals of a channel (e.g. separate cabling).
6.8.1.2 Safety interface X11
The X11 safety interface is wired internally to the SIB.
Pin Description Function

1 SIB test output A Makes the pulsed voltage avail-
3 able for the individual interface
(test signal)
inputs of channel A.
5
7 These signals may only be
mapped with the SIB.
9

6 Planning

19 SIB test output B Makes the clocked voltage
21 available for the individual
(test signal)
interface inputs of channel B.
23
25 These signals may only be
mapped with the SIB.
27
8 Safe operational stop, channel Safe operational stop input for
A all axes
26 Safe operational stop, channel Activation of standstill monitor-
B ing
Stop 0 is initiated if the acti-
vated monitoring is violated.
10 Safety stop, Stop 2 channel A Safety stop (Stop 2) input for all
28 Safety stop, Stop 2 channel B axes
Triggering of Stop 2 and activa-
tion of standstill monitoring at
standstill of all axes.
Stop 0 is initiated if the acti-
vated monitoring is violated.
37 Local E-STOP channel A Output, floating contacts from
38 internal E-STOP (>>> "SIB
outputs" Page 35)
55 Local E-STOP channel B
56 The contacts are closed if the
following conditions are met:
 E-STOP on smartPAD not
actuated
 Controller switched on and
operational
The contacts open if any condi-
tion is not met.
2 External E-STOP channel A Dual-channel E-STOP input
20 External E-STOP channel B (>>> "SIB inputs" Page 36)
Triggering of the E-STOP func-
tion in the robot controller.
6 Acknowledge operator safety, For connection of a dual-chan-
channel A nel input for acknowledging
24 Acknowledge operator safety, operator safety with floating
channel B contacts (>>> "SIB inputs"
Page 36)
The response of the “Operator
safety acknowledgement” input
can be configured in the KUKA
system software.
After closing the safety gate
(operator safety), manipulator
motion can be enabled in the
automatic modes using an
acknowledge button outside
the safety fence. This function
is deactivated on delivery.

KR C4; KR C4 CK

4 Operator safety, channel A For 2-channel connection of a
22 Operator safety, channel B safety gate locking mecha-
nism (>>> "SIB inputs"
Page 36)
As long as the signal is active,
the drives can be switched on.
Only effective in the AUTO-
MATIC modes.
41 Peri enabled channel A Output, floating contact
42 (>>> "SIB outputs" Page 35)
59 Peri enabled channel B (>>> "Signal “Peri enabled”
60 (PE)" Page 94)
39 Acknowledge operator safety, Output, floating contact for
40 channel A operator safety acknowledge-
ment (>>> "SIB outputs"
57 Acknowledge operator safety,
Page 35)
58 channel B
Relaying of the acknowledge
operator safety input signal to
other robot controllers at the
same safety fencing.
Signal “Peri The signal “Peri enabled” is set to 1 (active) if the following conditions are met:
enabled” (PE)  Drives are switched on.
 Safety controller motion enable signal present.
 The message “Operator safety open” must not be active.
This message is not active in the modes T1 and T2.
“Peri enabled” in conjunction with the signal “Safe operational stop”
 In the case of activation of the signal “Safe operational stop” during the
motion:
 Error -> braking with Stop 0. “Peri enabled” eliminated.
 Activation of the signal “Safe operational stop” with the manipulator sta-
tionary:
Release the brakes, switch drives to servo-control and monitor for restart.
“Peri enabled” remains active.
 Signal “Motion enable” remains active.
 US2 voltage (if present) remains active.
 Signal “Peri enabled” remains active.
“Peri enabled” in conjunction with the signal “Safety stop 2”
 In the case of activation of the signal “Safety stop 2”:
 Stop 2 of the manipulator.
 Signal “Drive enable” remains active.
 Brakes remain released.
 Manipulator remains under servo-control.
 Monitoring for restart active.
 Signal “Motion enable” is deactivated.
 US2 voltage (if present) is deactivated.
 Signal “Peri enabled” is deactivated.

6 Planning
6.8.1.3 X11 external enabling switch
Description External enabling switches can be connected to the robot controller via inter-
face X11.
Connector pin
allocation X11
11 CCU test output A Makes the pulsed voltage avail-
13 able for the individual interface
(test signal)
inputs of channel A.
These signals may only be
mapped with the CCU.
29 CCU test output B Makes the clocked voltage
31 available for the individual
(test signal)
interface inputs of channel B.
These signals may only be
mapped with the CCU.
12 External enabling 1 channel A For connection of an external
30 External enabling 1 channel B 2-channel enabling switch 1
with floating contacts.
If no external enabling switch 1
is connected, channel A pins
11/12 and channel B 29/30
must be jumpered. Only effec-
tive in TEST modes.
(>>> "Function of external axis
enabling switch" Page 95)
14 External enabling 2 channel A For connection of an external
32 External enabling 2 channel B 2-channel enabling switch 2
with floating contacts.
If no external enabling switch 2
is connected, channel A pins
13/14 and channel B 31/32
must be jumpered. Only effec-
tive in TEST modes.
(>>> "Function of external axis
enabling switch" Page 95)
Function of  External enabling 1

external axis Enabling switch must be pressed for jogging in T1 or T2. Input is closed.
enabling switch  External enabling 2
Enabling switch is not in the panic position. Input is closed.
 If a smartPAD is connected, its enabling switches and the external en-
abling are ANDed.
Function External External

Switch position
(only active for T1 and T2) enabling 1 enabling 2
Safety stop 1 (drives switched off Input open Input open No operational
when axis at standstill) state
Safety stop 2 (safe operational stop, Input open Input closed Not pressed
drives switched on)
Safety stop 1 (drives switched off Input closed Input open Panic position
when axis at standstill)
Axes enabled (axis jogging possible) Input closed Input closed Center position

KR C4; KR C4 CK
6.8.1.4 Wiring example for E-STOP circuit and safeguard
Description The EMERGENCY STOP devices are connected to X11 in the robot control-
ler.
EMERGENCY
The EMERGENCY STOP devices on the robot controller
STOP must be integrated into the EMERGENCY STOP circuit
of the system by the system integrator.
Failure to do this may result in death, severe injuries or considerable damage
to property.
Fig. 6-41: Wiring example: EMERGENCY STOP
Safety gate A dual-channel acknowledge button must be installed outside the physical
safeguard. The closing of the safety gate must be confirmed by pressing the
acknowledge button before the industrial robot can be started again in Auto-
matic mode.
The safety gate on the robot controller must be integrat-

ed into the safeguard circuit of the system by the system
integrator.
Failure to do this may result in death, severe injuries or considerable damage
to property.

6 Planning
Fig. 6-42: Wiring example: Operator safety with safety gate
6.8.1.5 Wiring examples for safe inputs and outputs
Safe input The switch-off capability of the inputs is monitored cyclically.

The inputs of the SIB are of dual-channel design with external testing. The
dual-channel operation of the inputs is monitored cyclically.
The following diagram illustrates the connection of a safe input to a floating
contact provided by the customer.
Fig. 6-43: Connection schematic for safe input
1 Safe input, SIB

2 SIB/CIB
3 Robot controller
4 Interface X11 or X13
5 Test output channel B
6 Test output channel A
7 Input X, channel A
8 Input X, channel B

KR C4; KR C4 CK
9 System side
10 Floating contact
Test outputs A and B are fed with the supply voltage of the SIB. Test outputs
A and B are sustained short-circuit proof. The test outputs must only be used
to supply the SIB inputs, and for no other purpose.
The wiring example described can be used to achieve compliance with Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.
Dynamic testing  The switch-off capability of the inputs is tested cyclically. For this, the test
outputs TA_A and TA_B are switched off alternately.
 The switch-off pulse length is defined for the SIBs as t1 = 625 μs (125 μs
– 2.375 ms).
 The duration t2 between two switch-off pulses on one channel is 106 ms.
 The input channel SIN_x_A must be supplied by the test signal TA_A. The
input channel SIN_x_B must be supplied by the test signal TA_B. No other
power supply is permissible.
 It is only permitted to connect sensors which allow the connection of test
signals and which provide floating contacts.
 The signals TA_A and TA_B must not be significantly delayed by the
switching element.
Switch-off pulse
diagram
Fig. 6-44: Switch-off pulse diagram, test outputs
t1 Switch-off pulse length

t2 Switch-off period per channel (106 ms)
t3 Offset between switch-off pulses of both channels (53 ms)
TA/A Test output channel A
TA/B Test output channel B
SIN_X_A Input X, channel A
SIN_X_B Input X, channel B
Safe output On the SIB, the outputs are provided as dual-channel floating relay outputs.
The following diagram illustrates the connection of a safe output to a safe input
provided by the customer with external test facility. The input used by the cus-
tomer must be monitored externally for cross-connection.

6 Planning
Fig. 6-45: Connection schematic for safe output
1 SIB
2 Robot controller
3 Interface X11 or X13
4 Output wiring
5 System side
6 Safe input (Fail Safe PLC, safety switching device)
7 Test output channel B
8 Test output channel A
9 Input X, channel A
10 Input X, channel B
The wiring example described can be used to achieve compliance with Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.
6.9 Ethernet interfaces
6.9.1 Safety functions via Ethernet safety interface
Description The exchange of safety-relevant signals between the controller and the sys-
tem is carried out via the Ethernet safety interface (e.g. PROFIsafe or CIP
Safety). The assignment of the input and output states within the Ethernet
safety interface protocol are listed below. In addition, non-safety-oriented in-
formation from the safety controller is sent to the non-safe section of the high-
er-level controller for the purpose of diagnosis and control.
Reserved bits Reserved safe inputs can be pre-assigned by a PLC with the values 0 or 1. In
both cases, the manipulator will move. If a safety function is assigned to a re-
served input (e.g. in the case of a software update) and if this input is preset
with the value 0, then the manipulator either does not move or comes unex-
pectedly to a standstill.
KUKA recommends pre-assignment of the reserved inputs with 1. If

a reserved input has a new safety function assigned to it, and the in-
put is not used by the customer’s PLC, the safety function is not acti-
vated. This prevents the safety controller from unexpectedly stopping the
manipulator.

KR C4; KR C4 CK
Input byte 0
Bit Signal Description
0 RES Reserved 1
The value 1 must be assigned to the input.
1 NHE Input for external Emergency Stop
0 = external E-STOP is active
1 = external E-STOP is not active
2 BS Operator safety
0 = operator safety is not active, e.g. safety gate open
1 = operator safety is active
3 QBS Acknowledgement of operator safety
Precondition for acknowledgment of operator safety
is the signal "Operator safety active" set in the BS bit.
Note: If the “BS” signal is acknowledged by the sys-
tem, this must be specified under Hardware options
in the safety configuration. Information is contained in
the Operating and Programming Instructions for Sys-
tem Integrators.
0 = operator safety has not been acknowledged
Edge 0 ->1 = operator safety has been acknowledged
4 SHS1 Safety STOP 1 (all axes)
 FF (motion enable) is set to 0.
 Voltage US2 is switched off.
 AF (drives enable) is set to 0 after 1.5 s.
Cancelation of this function does not require acknowl-
edgement.
This function is not permissible for the EMERGENCY
STOP function.
0 = safety stop is active
1 = safety stop is not active
5 SHS2 Safety STOP 2 (all axes)
 FF (motion enable) is set to 0.
 Voltage US2 is switched off.
edgement.
STOP function.
0 = safety stop is active
1 = safety stop is not active
6 RES -
7 RES -

6 Planning
Input byte 1
0 US2 Supply voltage US2 (signal for switching the second
supply voltage, US2, without battery backup)
If this output is not used, it should be set to 0.
0 = switch off US2
1 = Switch on US2
Note: Whether and how input US2 is used must be
specified under Hardware options in the safety con-
figuration. Information is contained in the Operating
and Programming Instructions for System Integra-
tors.
1 SBH Safe operational stop (all axes)
Prerequisite: All axes are stationary
edgement.
STOP function.
0 = safe operational stop is active.
1 = safe operational stop is not active.
2 RES Reserved 11
3 RES Reserved 12
4 RES Reserved 13
5 RES Reserved 14
6 RES Reserved 15
7 SPA System Powerdown Acknowledge
The system confirms that it has received the power-
down signal. A second after the “SP” (System Power-
down) signal has been set by the controller, the
requested action is executed, without the need for
confirmation from the PLC, and the controller shuts
down.
0 = confirmation is not active
1 = confirmation is active

KR C4; KR C4 CK
Output byte 0
0 NHL Local E-STOP (local E-STOP triggered)
0 = local E-STOP is active
1 = local E-STOP is not active
1 AF Drives enable (the internal safety controller in the
KRC has enabled the drives so that they can be
switched on)
0 = drives enable is not active (the robot controller
must switch the drives off)
1 = drives enable is active (the robot controller must
switch the drives to servo-control)
2 FF Motion enable (the internal safety controller in the
KRC has enabled robot motions)
0 = motion enable is not active (the robot controller
must stop the current motion)
1 = motion enable is active (the robot controller may
trigger a motion)
3 ZS The signal ZS (enabling) is set to 1 (active) if the fol-
lowing conditions are met:
 One of the enabling switches on the smartPAD is
in the center position (enabling signal has been is-
sued).
 T1 or T2 mode
 External enabling signal has been issued (signal
ZSE1/ZSE2).
 Robot can be moved (no external EMERGENCY
STOP, safety stop, etc.).
4 PE The signal “Peri enabled” is set to 1 (active) if the fol-
lowing conditions are met:
 Drives are switched on.
 Safety controller motion enable signal present.
 The message “Operator safety open” must not be
active.
(>>> "Signal “Peri enabled” (PE)" Page 94)
5 AUT The manipulator is in AUT or AUT EXT mode.
0 = AUT or AUT EXT mode is not active
1 = AUT or AUT EXT mode is active
6 T1 The manipulator is in Manual Reduced Velocity
mode.
0 = T1 mode is not active
1 = T1 mode is active
7 T2 The manipulator is in Manual High Velocity mode.
0 = T2 mode is not active
1 = T2 mode is active

6 Planning
Output byte 1
0 NHE External E-STOP has been triggered.
0 = external E-STOP is active
1 = external E-STOP is not active
1 BSQ Operator safety acknowledged
0 = operator safety is not assured
1 = operator safety is assured (input BS = 1 and, if
configured, input QBS acknowledged)
2 SHS1 Safety stop 1 (all axes)
0 = Safety stop 1 is not active
1 = Safety stop 1 is active (safe state reached)
3 SHS2 Safety stop 2 (all axes)
0 = Safety stop 2 is not active
1 = Safety stop 2 is active (safe state reached)
4 RES Reserved 13
5 RES Reserved 14
6 PSA Safety interface active
Precondition: An Ethernet interface must be installed
on the controller, e.g. PROFINET or Ethernet/IP
0 = safety interface is not active
1 = safety interface is active
7 SP System Powerdown (controller will be shut down)
One second after the SP signal has been set, the
PSA output is reset by the robot controller, without
confirmation from the PLC, and the controller is shut
down.
0 = controller on safety interface is active.
1 = controller will be shut down
6.9.1.1 Schematic circuit diagram for enabling switches
Description An external enabling switch can be connected to the higher-level safety con-
troller. The signals (ZSE make contact and External panic break contact) must
be correctly linked to the Ethernet safety interface signals in the safety control-
ler. The resulting Ethernet safety interface signals must then be routed to the
PROFIsafe of the KR C4. The response to the external enabling switch is then
identical to that for a discretely connected X11.
Signals
Fig. 6-46: Schematic circuit diagram of external enabling switch
 Enabling switch center position (make contact closed (1) = enabled) OR

AUT at SHS2

KR C4; KR C4 CK
 Panic (break contact open (0) = panic position) = AND not AUT at SHS1
6.9.1.2 SafeOperation via Ethernet safety interface (optional)
Description The components of the industrial robot move within the limits that have been
configured and activated. The actual positions are continuously calculated and
monitored against the safety parameters that have been set. The safety con-
troller monitors the industrial robot by means of the safety parameters that
have been set. If a component of the industrial robot violates a monitoring limit
or a safety parameter, the manipulator and external axes (optional) are
stopped. The Ethernet safety interface can be used, for example, to signal a
violation of safety monitoring functions.
In the case of the KR C4 compact robot controller, safety options such as Sa-
feOperation are only available via the Ethernet safety interface from
KSS/VSS 8.3 onwards.
Reserved bits Reserved safe inputs can be pre-assigned by a PLC with the values 0 or 1. In
both cases, the manipulator will move. If a safety function is assigned to a re-
served input (e.g. in the case of a software update) and if this input is preset
with the value 0, then the manipulator either does not move or comes unex-
pectedly to a standstill.
KUKA recommends pre-assignment of the reserved inputs with 1. If

a reserved input has a new safety function assigned to it, and the in-
put is not used by the customer’s PLC, the safety function is not acti-
vated. This prevents the safety controller from unexpectedly stopping the
manipulator.
Input byte 2 Bit Signal Description

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

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

6 Planning
Input byte 4
0…7 UER1 … 8 Monitoring spaces 1 … 8
Assignment: Bit 0 = monitoring space 1 … bit 7
= monitoring space 8
0 = monitoring space is active.
1 = monitoring space is not active.

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

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

0…7 WZ9 … 16 Tool selection 9 … 16
Assignment: Bit 0 = tool 9 … bit 7 = tool 16
0 = tool is not active.
1 = tool is active.
Exactly one tool must be selected at all times.
Output byte 2 Bit Signal Description

0 SO Safety option active
Activation status of the safety option
0 = safety option is not active
1 = safety option is active
1 RR Manipulator referenced
Mastering test display
0 = mastering test required.
1 = mastering test performed successfully.
2 JF Mastering error
Space monitoring is deactivated because at
least one axis is not mastered.
0 = mastering error. Space monitoring has been
deactivated.
1 = no error.

KR C4; KR C4 CK

3 VRED Reduced axis-specific and Cartesian velocity
(activation status of reduced velocity monitor-
ing)
0 = reduced velocity monitoring is not active.
1 = reduced velocity monitoring is active.
4…7 SBH1 … 4 Activation status of safe operational stop for
axis group 1 ... 4
group 4
Output byte 3
0…1 SBH5 … 6 Activation status of safe operational stop for
axis group 5 ... 6
group 6
2 SOS Safe Operation Stop
0 = a safety function has triggered a stop. The
output remains in the “0” state for at least
200 ms.
1 = none of the safety functions has triggered a
stop.
Note: The output SOS is available in System
Software 8.3 or higher. In System Software 8.2
or lower, bit 2 is a spare bit.
Output byte 4
0…7 MR1 … 8 Alarm space 1 … 8
Assignment: Bit 0 = alarm space 1 (associated
monitoring space 1) … bit 7 = alarm space 8
(associated monitoring space 8)
0 = monitoring space is violated.
1 = monitoring space is not violated.
Note: An inactive monitoring space is consid-
ered to be violated by default, i.e. in this case
the associated safe output MRx has the state
“0”.

6 Planning
Output byte 5
0…7 MR9 … 16 Alarm space 9 … 16
Assignment: Bit 0 = alarm space 9 (associated
monitoring space 9) … bit 7 = alarm space 16
(associated monitoring space 16)
0 = monitoring space is violated.
1 = monitoring space is not violated.
Note: An inactive monitoring space is consid-
ered to be violated by default, i.e. in this case
the associated safe output MRx has the state
“0”.
Output byte 6
Output byte 7
6.9.1.3 X66 Ethernet interface (RJ45)
Description Interface X66 is used for connecting an external computer to the KUKA Line
Interface for the purpose of installation, programming, debugging and diagno-
sis.
Necessary  RJ45 connector

equipment
Fig. 6-47: RJ-45 pin assignment
 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5E
 Maximum cable cross-section: AWG22
Connector pin 10BASE-T, 100BASE-TX allo-

allocation X66 Pin 1000BASE-TX allocation
cation
1 RX+ BI_DB+
2 RX- BI_DB-
3 TX+ BI_DA+
4 - BI_DD+

KR C4; KR C4 CK
10BASE-T, 100BASE-TX allo-

Pin 1000BASE-TX allocation
cation
5 - BI_DD-
6 TX- BI_DA-
7 - BI_DC+
8 - BI_DC-
6.10 EtherCAT connection on the CIB
Description Connector X44 on the CIB is the interface for connection of EtherCAT slaves
inside the robot controller (on the mounting plate for customer components).
The EtherCAT line remains in the robot controller. The EtherCAT line can be
routed out of the robot controller via the optional connector X65. Information
about connector X65 can be found in the assembly and operating instructions
of the optional KR C4 interfaces.
The EtherCAT devices must be configured with WorkVisual.
Fig. 6-48: EtherCAT connection X44
1 CIB
2 EtherCAT connection X44
6.11 PE equipotential bonding
Description The following cables must be connected before start-up:
 A 16 mm2 cable as equipotential bonding between the manipulator/robot

kinematic system and the robot controller.
 An additional 16 mm2 PE conductor between the central PE rail of the sup-
ply cabinet and the PE bolt of the robot controller.

6 Planning
Fig. 6-49: Equipotential bonding from robot controller to manipulator via

cable duct
1 PE to central PE rail of the supply cabinet

2 Connection panel on robot controller
3 Equipotential bonding connection on the manipulator
4 Equipotential bonding from the robot controller to the manipulator
5 Cable duct
6 Equipotential bonding from the start of the cable duct to the main equi-
potential bonding
7 Main equipotential bonding
8 Equipotential bonding from the end of the cable duct to the main equi-
potential bonding
Fig. 6-50: Equipotential bonding, robot controller - manipulator
1 PE to central PE rail of the supply cabinet

2 Connection panel on robot controller
3 Equipotential bonding from the robot controller to the manipulator
4 Equipotential bonding connection on the manipulator

KR C4; KR C4 CK
6.12 Modifying the system configuration, exchanging devices
Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
 Installation of KSS/VSS 8.2 or higher
This is the case if KSS/VSS 8.2 or higher is installed without KSS/VSS 8.2
or higher already being present (because it has been uninstalled or delet-
ed or has never been installed).
 The hard drive has been exchanged.
 A device has been replaced by a device of a different type.
 More than one device has been replaced by a device of a different type.
 One or more devices have been removed.
 One or more devices have been added.
Exchanging If a device is exchanged, at least one KCB, KSB or KEB device is replaced by
devices a device of the same type. Any number of KCB, KSB and KEB devices can be
exchanged until all devices in the KCB, KSB and KEB have been replaced si-
multaneously by devices of the same type. Simultaneous exchange of two
identical components of the KCB is not possible. Only one of the identical com-
ponents may be exchanged at any one time.
The interchanging of 2 identical devices can only occur in the case of

the KSP3x40 if the current system configuration contains 2 KSP3x40.
6.13 Operator safety acknowledgement
A dual-channel acknowledge button must be installed outside the physical

safeguard. The closing of the safety gate must be confirmed by pressing the
acknowledge button before the industrial robot can be started again in Auto-
matic mode.
6.14 Performance level
The safety functions of the robot controller conform to Category 3 and Perfor-
mance Level d according to EN ISO 13849-1.
6.14.1 PFH values of the safety functions
The safety values are based on a service life of 20 years.

The PFH value classification of the controller is only valid if the E-STOP device
is tested at least once every 12 months.
When evaluating system safety functions, it must be remembered that the
PFH values for a combination of multiple controllers may have to be taken into
consideration more than once. This is the case for RoboTeam systems or
higher-level hazard areas. The PFH value determined for the safety function
at system level must not exceed the limit for PL d.
The PFH values relate to the specific safety functions of the different controller
variants.
Safety function groups:
 Standard safety functions
 Operating mode selection
 Operator safety

6 Planning
 EMERGENCY STOP device

 Enabling device
 External safe operational stop
 Control of the peripheral contactor
 Safety functions of KUKA Safe Operation Technology (optional)
 Monitoring of axis spaces
 Monitoring of Cartesian spaces
 Monitoring of axis velocity
 Monitoring of Cartesian velocity
 Monitoring of axis acceleration
 Safe operational stop
 Tool monitoring
Overview of controller variant PFH values:
Robot controller variant PFH value

KR C4; KR C4 CK < 1 x 10-7
KR C4 midsize; KR C4 midsize CK < 1 x 10-7
KR C4 extended; KR C4 extended CK < 1 x 10-7
KR C4 NA; KR C4 CK NA < 1 x 10-7
KR C4 NA variant: TTE1 < 1 x 10-7
KR C4 NA extended; KR C4 CK NA extended < 1 x 10-7
KR C4 variant: TBM1 < 1 x 10-7
KR C4 variants: TDA1; TDA2; TDA3; TDA4 < 1 x 10-7
KR C4 variants: TFO1; TFO2 < 2 x 10-7
KR C4 variants: TRE1; TRE2 < 1.7 x 10-7
KR C4 variant: TRE3 < 1 x 10-7
KR C4 variants: TVO1; TVO2; TVO3 < 1 x 10-7
VKR C4 variants: TVW1; TVW2; TVW3; TVW4 < 1 x 10-7
VKR C4 Retrofit
 Without external EMERGENCY STOP and operator < 1 x 10-7
safety functions
 External EMERGENCY STOP and operator safety 5 x 10-7
functions
KR C4 Panel Mounted < 1 x 10-7
KR C4 compact < 1 x 10-7
KR C4 smallsize < 1 x 10-7
KR C4 smallsize-2 < 1 x 10-7
KR C4 smallsize-2 with KR C4 smallsize drive box < 1 x 10-7
For controller variants that are not listed here, please contact KUKA
Roboter GmbH.

KR C4; KR C4 CK

7 Transportation
7
T
Transportation
s
7.1 Transportation using lifting tackle

t
Precondition  The robot controller must be switched off.

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

equipment  4 eyebolts
Recommendation:
M10 eyebolts acc. to DIN 580 with the following properties:
 Screw thread: M10
 Material: C15E
 Inside/outside diameter: 25 mm/45 mm
 Thread length: 17 mm
 Pitch: 1.5 mm
 Load-bearing capacity: 230 kg
Procedure 1. Screw the eyebolts into the robot controller. The eyebolts must be fully
screwed in and flush with the mounting surface.
2. Attach the lifting tackle with or without a lifting frame to all 4 eyebolts on
the robot controller.

KR C4; KR C4 CK
Fig. 7-1: Transportation using lifting tackle
1 Eyebolts on the robot controller

2 Correctly attached lifting tackle
3 Correctly attached lifting tackle
4 Incorrectly attached lifting tackle
3. Attach the lifting tackle to the crane.
If the suspended robot controller is transported too quick-

ly, it may swing and cause injury or damage. Transport
the robot controller slowly.
4. Slowly lift and transport the robot controller.

5. Slowly lower the robot controller at its destination.
6. Unhook lifting tackle on the robot controller.
7.2 Transportation by fork lift truck


7 Transportation
Use of unsuitable handling equipment may result in dam-

age to the robot controller or injury to persons. Only use
authorized handling equipment with a sufficient load-bearing capacity. Only
transport the robot controller in the manner specified here.
Transportation The robot controller can be picked up using a fork lift truck. The robot controller
with standard must not be damaged when inserting the forks beneath the robot controller.
cabinet base After insertion, the forks of the fork lift truck must be opened until they are in
contact with the cabinet bases.
Fig. 7-2: Transportation with standard cabinet base
1 Standard cabinet base

2 Anti-toppling bracket
Transportation The robot controller can be picked up by fork lift truck using two fork slots (op-
using fork slots tion).
Avoid excessive loading of the fork slots through undue

inward or outward movement of hydraulically adjustable
forks of the fork lift truck. Failure to do so may result in material damage.
Fig. 7-3: Transportation with fork slots
1 Fork slots
Transportation The robot controller with transformer (option) can be picked up by fork lift truck
with transformer using two fork slots.

KR C4; KR C4 CK
Avoid excessive loading of the fork slots through undue

inward or outward movement of hydraulically adjustable
forks of the fork lift truck. Failure to do so may result in material damage.
Fig. 7-4: Transportation with transformer
1 Fork slots
2 Transformer
Transportation The robot controller with the set of rollers (option) can be picked up by fork lift
with the set of truck. For this, the forks of the fork lift truck must be inserted between the anti-
rollers toppling bracket and the cross-strut of the roller set.
Fig. 7-5: Transportation with the set of rollers
2 Cross-strut of the roller set
7.3 Transportation by pallet truck


7 Transportation
Transportation by
pallet truck
Fig. 7-6: Transportation by pallet truck
7.4 Transportation with set of rollers (optional)
Description The robot controller rollers may only be used to roll the cabinet into and out of
a row of cabinets – not to transport the cabinet over longer distances. The floor
must be level and free from obstacles, as there is a permanent risk of toppling.
If the robot controller is towed by a vehicle (fork lift truck,

electrical vehicle), this can result in damage to the rollers
and to the robot controller. The robot controller must not be hitched to a ve-
hicle and transported using its rollers.

KR C4; KR C4 CK

8 Start-up and recommissioning

t
8.1 Start-up overview
This is an overview of the most important steps during start-up. The

precise sequence depends on the application, the manipulator type,
the technology packages used and other customer-specific circum-
stances.
For this reason, the overview does not claim to be comprehensive.
This overview refers to the start-up of the industrial robot. The start-
up of the overall system is not within the scope of this documentation.
Manipulator
Step Description Information

1 Carry out a visual inspection of the manipula- Detailed information is contained
tor. in the operating or assembly
2 Install the manipulator mounting base (mount- instructions for the manipulator, in
ing base, machine frame mounting or booster the chapter “Start-up and recom-
frame). missioning”.
3 Install the manipulator.
Electrical system

4 Carry out a visual inspection of the robot con- -
troller.
5 Make sure that no condensation has formed in -
the robot controller.
6 Install the robot controller. (>>> 8.2 "Installing the robot con-
troller" Page 120)
7 Connect the connecting cables. (>>> 8.3 "Connecting the con-
necting cables" Page 121)
8 Plug in the KUKA smartPAD. (>>> 8.5 "Plugging in the KUKA
smartPAD" Page 122)
9 Connect the equipotential bonding between the (>>> 8.6 "Connecting the PE
manipulator and the robot controller. equipotential bonding" Page 122)
10 Connect the robot controller to the power sup- (>>> 8.7 "Power supply connec-
ply. tion via X1 Harting connector"
Page 123)
11 Reverse the battery discharge protection mea- (>>> 8.8 "Reversing the battery
sures. discharge protection measures"
Page 123)
12 Configure and connect safety interface X11. (>>> 8.9 "Configuring and con-
necting safety interface X11"
Page 124)
13 Configure Ethernet safety interface X66. (>>> 6.9.1 "Safety functions via
Ethernet safety interface"
Page 99)
14 Drive configuration modified (>>> 8.10 "Modifying the system
configuration, exchanging
devices" Page 124)

KR C4; KR C4 CK

15 Start-up mode (>>> 8.11 "Start-up mode"
Page 125)
16 Switch on the robot controller. (>>> 8.12 "Switching on the robot
controller" Page 126)
17 Check the safety equipment. Detailed information is contained
in the operating and assembly
instructions for the robot controller,
in the “Safety” chapter.
18 Configure the inputs/outputs between the robot Detailed information can be found
controller and the periphery. in the field bus documentation.
Software

19 Check the machine data. Detailed information is contained
20 Master the manipulator without a load. in the operating and programming
instructions.
21 Mount the tool and master the manipulator with
a load.
22 Check the software limit switches and adapt
them if required.
23 Calibrate the tool.
In the case of a stationary tool: Calibrate an
external TCP.
24 Enter the load data.
25 Calibrate the base (optional).
In the case of a stationary tool: Calibrate the
workpiece (optional).
26 If the manipulator is to be controlled by a host Detailed information is contained
computer or PLC: configure Automatic External in the Operating and Programming
interface. Instructions for System Integra-
tors.
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 manipulator. Further-
more, the long text names can be updated in application programs.
Accessories Precondition: the manipulator is ready to move, i.e. the software start-up has
been carried out up to and including the item “Master the manipulator without
load”.
Description Information
Optional: install and adjust external energy supply system, Detailed information can be found
taking the programming into consideration. in the energy supply system docu-
mentation.
Positionally accurate manipulator option: check data.
8.2 Installing the robot controller
Procedure 1. Install the robot controller. The minimum clearances to walls, other cabi-
nets, etc. must be observed.
2. Check the robot controller for any damage caused during transportation.

3. Check that fuses, contactors and boards are fitted securely.

4. Secure any modules that have come loose.
5. Check that all screwed and clamped connections are securely fastened.
6. The operator must cover the warning label Read manual with the label in
the relevant local language. (>>> 4.9 "Plates and labels" Page 39)
8.3 Connecting the connecting cables
Overview  A connecting cable set is supplied with the industrial robot. In the standard
version this consists of:
 Motor cables to the manipulator
 Data cables to the manipulator
 The following cables may be provided for additional applications:
 Motor cables for external axes
 Peripheral cables
Bending radius The following bending radii must be observed:

 Fixed installation: 3 ... 5 x cable diameter.
 Installation in cable carrier: 7 ... 10 x cable diameter (cable must be spec-
ified for this).
Procedure
The robot controller is preconfigured for the specific in-
dustrial robot. If cables are interchanged, the manipula-
tor and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.
Route the connecting cables between the robot and the

control cabinet in such a way as to exclude the possibility
of damage to the cables.
1. Route and connect the motor cables to the manipulator junction box sep-
arately from the data cables.
2. Route and connect the motor cables of the external axes.
Following a defect with subsequent exchange of the data

cable, the mastering may be incorrect. This may cause
personal injury or material damage. Following an exchange of the data cable,
carry out mastering or perform a mastering test of all axes.
3. Route the data cables to the manipulator junction box separately from the
motor cable. Plug in connector X21.
4. Connect the peripheral cables.
Fig. 8-1: Example: Installing the cables in the cable duct

KR C4; KR C4 CK
1 Cable duct 4 Motor cables

2 Separating webs 5 Data cables
3 Welding cables
8.3.1 Data cables, X21

allocation for X21
2 +24 V PS1
3 GND
9 TPF0_P
10 TPFI_P
11 TPF0_N
12 TPFI_N
8.4 Fastening the KUKA smartPAD holder (optional)
Procedure  Fasten the smartPAD holder on the door of the robot controller or on the
wall. (>>> 6.4 "Fastening the KUKA smartPAD holder (optional)"
Page 72)
8.5 Plugging in the KUKA smartPAD
Description The KUKA smartPAD is connected to interface X19.
Procedure  Plug the KUKA smartPAD to X19 on the robot controller.
If the smartPAD is disconnected, the system can no lon-

ger be switched off by means of the EMERGENCY
STOP device on the smartPAD. For this reason, an external EMERGENCY
STOP must be connected to the robot controller.
The user is responsible for ensuring that the smartPAD is immediately re-
moved from the system when it has been disconnected. The smartPAD must
be stored out of sight and reach of personnel working on the industrial robot.
This prevents operational and non-operational EMERGENCY STOP devices
from becoming interchanged.
Failure to observe these precautions may result in death, injuries or damage
to property.

allocation X19
11 TD+
12 TD-
2 RD+
3 RD-
8 smartPAD plugged in (A) 0 V
9 smartPAD plugged in (B) 24 V
5 24 V PS2
6 GND
8.6 Connecting the PE equipotential bonding
Procedure 1. Connect an additional 16 mm2 PE conductor between the central PE rail

of the supply cabinet and the PE bolt of the robot controller.

2. Connect a 16 mm2 cable as equipotential bonding between the manipula-

tor and the robot controller.
3. Carry out a ground conductor check for the entire industrial robot in accor-
dance with EN 60204-1.
8.7 Power supply connection via X1 Harting connector
Description The robot controller is connected to the mains via a Harting connector X1.

without a grounded neutral, this may cause malfunc-
tions in the robot controller and material damage to the power supply units.
Electrical voltage can cause injuries. The robot controller may only be oper-
ated with grounded-neutral power supply systems.
Precondition  The robot controller is switched off.

 The power cable is de-energized.
Procedure  Connect the robot controller to the power supply via X1.

allocation X1
1 L1
2 L2
3 L3
PE PE
8.8 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 X305 dis-
connected from the CCU.
Procedure  Plug connector X305 into the CCU.

KR C4; KR C4 CK
Fig. 8-2: Battery discharge protection X305
1 Connector X305 on the CCU
8.9 Configuring and connecting safety interface X11
Precondition  The robot controller is switched off.
Procedure 1. Configure connector X11 in accordance with the system and safety con-
cepts. (>>> 6.8.1 "Description of safety interface X11" Page 92)
2. Connect interface connector X11 to the robot controller.
Connector X11 may only be plugged in or unplugged

when the robot controller is switched off. If connector
X11 is plugged in or unplugged when energized, damage to property may oc-
cur.

8.11 Start-up mode
Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 without the external
safeguards being put into operation.
When Start-up mode is possible depends on the safety interface that is used.
Discrete safety interface
 System Software 8.2 or earlier:
Start-up mode is always possible if all input signals at the discrete safety
interface have the state “logic zero”. If this is not the case, the robot con-
troller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the in-
puts there must also have the state “logic zero”.
 System Software 8.3 or higher:
Start-up mode is always possible. This also means that it is independent
of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection to a
higher-level safety system exists or is established.
Hazards Possible hazards and risks involved in using Start-up mode:

 A person walks into the manipulator’s danger zone.
 In a hazardous situation, a disabled external EMERGENCY STOP device
is actuated and the manipulator is not shut down.
Additional measures for avoiding risks in Start-up mode:
 Cover disabled EMERGENCY STOP devices or attach a warning sign in-
dicating that the EMERGENCY STOP device is out of operation.
 If there is no safety fence, other measures must be taken to prevent per-
sons from entering the manipulator’s danger zone, e.g. use of warning
tape.
External safeguards are disabled in Start-up mode. Ob-

serve the safety instructions relating to Start-up mode.
(>>> 5.8.3.2 "Start-up mode" Page 60)
In Start-up mode, the system switches to the following simulated input image:
 The external EMERGENCY STOP is not active.
 The safety gate is open.
 No safety stop 1 has been requested.
 No safety stop 2 has been requested.
 No safe operational stop has been requested.
 Only for VKR C4: E2 is closed.
If SafeOperation or SafeRangeMonitoring is used, Start-up mode also influ-
ences other signals.
Information about the effects of Start-up mode in conjunction with Sa-

feOperation or SafeRangeMonitoring can be found in the documen-
tation SafeOperation and SafeRangeMonitoring.

KR C4; KR C4 CK
Mapping of standard signals:

Byte 0: 0100 1110
Byte 1: 0100 0000
SafeOperation or SafeRangeMonitoring signal mapping:
Byte 2: 1111 1111
Byte 3: 1111 1111
Byte 4: 1111 1111
Byte 5: 1111 1111
Byte 6: 1000 0000
Byte 7: 0000 0000
8.12 Switching on the robot controller
Precondition  The door of the robot controller is closed.

 All electrical connections are correct and the power supply is within the
specified limits.
 It must be ensured that no persons or objects are present within the dan-
ger zone of the manipulator.
 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.
We recommend that all motions of the manipulator should be trig-

gered from outside the safety fencing.
Procedure 1. Switch on the mains power to the robot controller.

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

9 Operation
9 Operation
9.1 KUKA smartPAD teach pendant

t
9.1.1 Front view
Function The smartPAD is the teach pendant for the industrial robot. The smartPAD has
all the operator control and display functions required for operating and pro-
gramming the industrial robot.
The smartPAD has a touch screen: the smartHMI can be operated with a fin-
ger or stylus. An external mouse or external keyboard is not necessary.
Overview
Fig. 9-1: KUKA smartPAD, front view

KR C4; KR C4 CK
Item Description
1 Button for disconnecting the smartPAD
2 Mode selector switch. The switch may be one of the following vari-
ants:
 With key
 Without key
The mode selector switch is used to call the connection manager.
The operating mode can be changed by using the connection man-
ager.
3 EMERGENCY STOP button. Stops the robot in hazardous situa-

tions. The EMERGENCY STOP button locks itself in place when it
is pressed.
4 Space Mouse: For moving the robot manually.
5 Jog keys: For moving the robot manually.
6 Key for setting the program override

7 Key for setting the jog override
8 Main menu key: Shows the menu items on the smartHMI
9 Status keys. The status keys are used primarily for setting param-
eters in technology packages. Their exact function depends on the
technology packages installed.
10 Start key: The Start key is used to start a program.
11 Start backwards key: The Start backwards key is used to start a
program backwards. The program is executed step by step.
12 STOP key: The STOP key is used to stop a program that is run-
ning.
13 Keyboard key
Displays the keyboard. It is generally not necessary to press this
key to display the keyboard, as the smartHMI detects when key-
board input is required and displays the keyboard automatically.

9 Operation
9.1.2 Rear view
Overview
Fig. 9-2: KUKA smartPAD, rear view
1 Enabling switch 4 USB connection

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

Rating plate Rating plate
Start key The Start key is used to start a program.
The enabling switch has 3 positions:
 Not pressed
 Center position
 Fully pressed (panic position)
Enabling
switch The enabling switch must be held in the center position
in operating modes T1 and T2 in order to be able to jog
the manipulator.
In the operating modes Automatic and Automatic Exter-
nal, the enabling switch has no function.
The USB connection is used, for example, for archiving
USB connec- and restoring data.
tion
Only for FAT32-formatted USB sticks.

KR C4; KR C4 CK

10 Maintenance
10 Maintenance
Description
t Maintenance work must be performed at the specified maintenance intervals
after commissioning at the customer’s plant.
10.1 Maintenance symbols
Maintenance
symbols
Oil change
Lubricate with grease gun
Lubricate with brush
Tighten screw/nut
Check component, visual inspection
Clean component
Exchange battery
Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
Cables routed from power supply connection X1 to the

main switch are energized even when the main switch is
switched off! This mains voltage can cause injuries on contact.

 Observe the ESD guidelines.

KR C4; KR C4 CK
Fig. 10-1: Maintenance points
Interval Item Activity

1 year 8 Check the utilized relay outputs of the SIB and/or Ex-
tended SIB for correct functioning
(>>> 10.2 "Checking SIB relay outputs" Page 133)
(>>> 10.3 "Checking Extended SIB relay outputs"
Page 133)
- Cyclical function test of operator safety and external
EMERGENCY STOP devices
1 year at 4 Depending on installation conditions and degree of
the latest fouling, clean the protective grille of the external fan
with a brush.
2 years at 1 Depending on installation conditions and degree of
the latest fouling, clean the heat exchanger with a brush.
3 Depending on installation conditions and degree of
fouling, clean the heat sinks of the KPP and KSPs
with a brush.
4 Depending on installation conditions and degree of
fouling, clean the external fan with a brush.
5 Depending on installation conditions and the degree
of fouling, clean the heat sink of the low-voltage pow-
er supply unit with a brush.
5 years 7 Exchange the motherboard battery
5 years 6 Exchange the control PC fan (>>> 11.5.2 "Ex-
(with 3-shift changing the control PC fan" Page 140)
operation) 4 Exchange the external fan (>>> 11.3 "Exchanging
the external fan" Page 137)
10 Exchange the internal fan, if present
(>>> 11.4 "Exchanging the internal fan" Page 138)

10 Maintenance
Interval Item Activity

As indicat- 9 Exchange the batteries (>>> 11.7 "Exchanging the
ed by the batteries" Page 158)
battery
monitoring
When pres- 2 Depends on installation conditions and degree of
sure relief fouling. Visual inspection of the pressure relief plug:
plug be- change filter insert if discolored (original color: white)
comes dis- (>>> 11.9 "Exchanging the pressure relief plug"
colored Page 163)
Once an activity from the maintenance list has been carried out, a visual in-
spection must be made, with special attention to the following points:
 Check that fuses, contactors, plug-in connections and boards are fitted se-
curely.
 Check cabling for damage.
 Check PE equipotential bonding connection.
 Check all system components for wear and damage.
10.2 Checking SIB relay outputs
Activity Check the function of the output “Local Emergency Stop”.
Procedure  Press the local EMERGENCY STOP device.
Activity Check the function of the output “Operator safety acknowledged”.
Procedure 1. Set operating mode to Automatic or Automatic External.

2. Open operator safety (safeguard).
Activity Check the function of the output “Switch on periphery”.
Procedure 1. Set operating mode to Automatic or Automatic External.

2. Open operator safety (safeguard).
3. Release enabling switch in “T1” or “T2” mode.
If no error message is displayed, the relay outputs are OK.
10.3 Checking Extended SIB relay outputs
Activity Check the alarm space outputs.
Procedure  Violate the corresponding alarm space. Depending on the configuration of

the alarm space, the Cartesian or axis-specific alarm space can be violat-
ed.
In normal operation, the alarm space outputs are checked cyclically

within the test interval (1 year) by the production operation.
Activity Check the output SafeOperation active.
Procedure  Deactivate SafeOperation or SafeRangeMonitoring.
Activity Check the output Robot referenced.
Procedure  Switch the drive bus off and back on again.

If no error message is displayed, the relay outputs are OK.

KR C4; KR C4 CK
10.4 Cleaning the robot controller
 The controller has been shut down.

Work regulations  The manufacturer’s instructions must be observed when using cleaning
agents for cleaning work.
 It must be ensured that no cleaning agents enter electrical components.
 Do not use compressed air during cleaning work.
 Do not spray with water.
Procedure 1. Loosen and vacuum up any dust deposits.

2. Clean the housing of the robot controller with a cloth soaked with a mild
cleaning agent.
3. Clean cables, plastic parts and hoses with a solvent-free cleaning agent.
4. Replace damaged, illegible or missing identifications, labels and plates.

11 Repair
11 Repair
11.1 Repair and procurement of spare parts
Repairs Repairs to the robot controller may only be carried out by KUKA customer sup-
port personnel or by customers who have taken part in a relevant course of
training held by KUKA Roboter GmbH.
Repairs within modules may only be carried out by specially trained KUKA Ro-
boter GmbH personnel.
Procurement of The article numbers of the spare parts are listed in the spare parts catalog.
spare parts KUKA Roboter GmbH supplies the following types of spare parts for repairs to
the robot controller:
 New parts
Once the new part has been installed, the part that has been removed can
be disposed of.
 Exchange parts
Once the exchange part has been installed, the part that has been re-
moved is returned to KUKA Roboter GmbH.
A “Robot Repair Card” is supplied with the exchange parts. The Re-
pair Card must be completed and returned to KUKA Roboter GmbH.

KR C4; KR C4 CK
11.2 Wiring example X11
Connector pin
allocation
Fig. 11-1: Wiring example X11
The enabling switch is a three-position switch with a panic position.

 Enabling switch center position (make contact closed = enabled)
 Panic (break contact open = panic position)
If wiring example X11 is used for start-up or trouble-

shooting, the connected safety components of the robot
system are disabled.

11 Repair
The industrial robot can be set to Start-up mode via the smartHMI
user interface. (>>> 8.11 "Start-up mode" Page 125) In this mode,
the manipulator can be moved in T1 mode without X11 being wired
up.
11.3 Exchanging the external fan
 The power cable must be de-energized.

Procedure 1. Unplug fan connector X14 on the CCU.

2. Remove the rear panel.
Fig. 11-2: Exchanging the external fan
1 Fastening of rear panel

2 Fan connector X14 on the CCU
3. Remove the screws of the cable inlet.

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

KR C4; KR C4 CK
Fig. 11-3: External fan, cable inlet
1 Fastening of cable inlet

2 Cover of the cable inlet
5. Remove the fan holder together with the fan.

6. Install the new fan together with its holder and fasten.
Fig. 11-4: Exchanging the external fan
1 Fastening of the fan holder
7. Route the connecting cable in the cabinet.

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


11 Repair
Description The internal fan is not installed in all cabinet variants. As as alternative to the
internal fan, a KPC cooling duct may be installed. (>>> 3.19 "Cabinet cooling"
Page 30) The internal fan is located in the lower left-hand corner of the control
cabinet.
Procedure 1. Unplug fan connector X962 from the fan module.
Fig. 11-5: Removing the fan module
1 Fastening screw 2 Connector X962
2. Loosen the fastening screw of the fan module.

3. Take off fan module.
4. Insert the new fan module and fasten it with the fastening screw.
5. Plug fan connector X962 into the fan module.
11.5 Exchanging control PC components
11.5.1 Exchanging the control PC
Precondition  Observe the ESD guidelines.

 From KSS 8.3 and from motherboard D3236-K onwards:
 Board Package USB stick in the USB port.
Procedure 1. Shut down the robot controller with the settings Cold start and Reload
files.
2. Turn off the robot controller using the main switch and take measures to
prevent it from being turned on again unintentionally.
3. Disconnect the power cable from the supply.

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

KR C4; KR C4 CK
Fig. 11-6: Fastening elements of the control PC
1 Knurled nut
2 Tilt the PC
3 Lift the PC
3b Rail
7. Insert the new control PC and fasten.

8. Plug in the connections.
For network cable connection, see (>>> 3.16 "Control PC interfaces"
Page 25)
9. Switch on the robot controller.
From KSS 8.3 and from motherboard D3236-K onwards:
 Once the controller has been successfully started, disconnect the
Board Package USB stick and carefully store it.
Starting and installing the drivers may take some time.
11.5.2 Exchanging the control PC fan

Procedure 1. Remove the control PC. (>>> 11.5.1 "Exchanging the control PC"
Page 139)
2. Remote air duct, if present.
3. Remove the control PC cover.
4. Release and unplug the fan connector. Depending on the variant, the fan
connector is located either on the housing or directly on the motherboard.

11 Repair
Fig. 11-7: Disconnect control PC fan from housing or motherboard
1 Fan connector 4 Fan grille

2 Control PC housing 5 CPU fan
3 Fans
5. Remove outer fan grille.

6. Pull the fan inwards off the mounting plugs.
7. Remove the expanding rivets and take off the inner fan grille.
Fig. 11-8: PC fan configuration
1 Mounting plugs 4 Fan grille (optional, depending

on variant)
2 Outer fan grille 5 Fan identification plate
3 Fastening of fan grille (ex-
panding rivets)
8. Fasten the inner fan grille to the new fan with the expanding rivets.
The fan grille must be fastened to the side with the identification plate.
See (>>> Fig. 11-8 )

KR C4; KR C4 CK
Fig. 11-9: Installing the control PC fan
1 Mounting plugs on the fan 3 Mounting plugs on the PC

housing
2 Fan grille
9. Install the mounting plugs in the fan.

10. Insert the fan into the PC housing and pull the mounting plugs through the
PC housing.
11. Reattach outer fan grille.
12. Install the air duct.
11.5.3 Exchanging the motherboard
A defective motherboard is not exchanged separately, but together with the

control PC.
11.5.4 Exchanging the motherboard battery
The battery on the motherboard of the control PC may only be exchanged by

authorized maintenance personnel in consultation with the KUKA customer
support service.
11.5.5 Exchanging the LAN Dual NIC network card

Description Depending on the control PC variant, the LAN Dual NIC network card is per-
manently integrated into the motherboard. In this case, if the LAN Dual NIC
network card is defective, the entire control PC must be exchanged.
If the LAN Dual NIC network card is plugged onto the motherboard, it can be
exchanged separately.
Procedure 1. Open the PC chassis.

11 Repair
2. Unplug the connections to the LAN Dual NIC network card.

3. Release the fastenings of the card and pull the card out of the slot.
4. Inspect the new LAN Dual NIC network card for mechanical damage.
5. Plug the LAN Dual NIC network card into its slot and tighten the fastening
screw.
6. Plug in the connections to the card.
11.5.6 Exchanging the hard drive

Procedure 1. Release and unplug the SATA connector.

2. Unplug power supply connector.
3. Unscrew the knurled screws and remove the hard drive.
4. Exchange the hard drive for a new one.
5. Plug in the SATA and power supply connectors.
6. Fasten the hard drive with the knurled screws.
7. Install the operating system and the KUKA System Software (KSS).
8. The system configuration of the industrial robot must be configured using
WorkVisual.
Once the hard drive has been exchanged, the following options are
available in addition to configuration using WorkVisual:
Load the archive of the previous installation.
 Restore the complete image using the KUKA Recovery Tool.
Fig. 11-10: Exchanging the hard drive
1 SATA connector
2 Power supply connector
3 Knurled screws on the underside

KR C4; KR C4 CK
Exchanging If a device is exchanged, at least one KCB, KSB or KEB device is replaced by
devices a device of the same type. Any number of KCB, KSB and KEB devices can be
exchanged until all devices in the KCB, KSB and KEB have been replaced si-
multaneously by devices of the same type. Simultaneous exchange of two
identical components of the KCB is not possible. Only one of the identical com-
ponents may be exchanged at any one time.
The interchanging of 2 identical devices can only occur in the case of

the KSP3x40 if the current system configuration contains 2 KSP3x40.
11.6.1 Exchanging the KUKA Power Pack
If removal is performed immediately after the robot con-

troller has been shut down, the heat sink surface temper-
atures are likely to be high and could result in burn injuries. Protective gloves
must be worn.


 Wait 5 minutes until the intermediate circuit has discharged.
The following components may remain energized (50-

780 V) up to 5 minutes after the robot controller has been
switched off:
 the KPP
 the KSPs
 connections for motor connector X20 and connected motor cables
 the intermediate circuit connecting cables
This voltage can cause life-threatening injuries.

11 Repair
Connections
Fig. 11-11: Connections KPP 1 / KPP 2
Item Connector Description

1 X30 Brakes power supply OUT
2 X20 Drive bus OUT
3 X10 Control electronics power supply OUT
4 X7 Ballast resistor
5 X6 DC link OUT
6 X11 Control electronics power supply IN
7 X21 Drive bus IN
8 X34 Brakes power supply IN
9 X3 Motor connection 3, axis 8
10 X33 Brake connection 3, axis 8
11 X32 Brake connection 2, axis 7
12 X2 Motor connection 2, axis 7
13 - Not used
14 X4 AC power supply connection and PE

KR C4; KR C4 CK
KPP 3 connec-
tions
Fig. 11-12: KPP 3 connections

2 X20 Drive bus OUT
4 X7 Ballast resistor
5 X6 DC link OUT
7 X21 Drive bus IN
9 X3 Motor connection 3
10 X33 Connection, brake 3
15 X4 AC power supply connection and PE
Procedure 1. Unlock connectors X20 and X21 of the data cables. Unplug all connections
to the KPP.
Unplugging the data cable connectors without first un-

locking them damages the connectors. Unlock the con-
nectors before unplugging them.

11 Repair
Fig. 11-13: Unlocking connectors X20 and X21
1 Connector unlocked 3 Connector plugged in and

locked
2 Connector locked 4 Connector plugged in and un-
locked
2. Slacken the Allen screws.
The KPP weighs approx. 10 kg. When removing or in-

stalling the KPP, care must be taken to avoid injury by
crushing. Protective gloves must be worn.
3. Lift the KPP slightly, tilt the top forwards and lift the KPP out of the support
bracket.
4. Insert the new KPP into the support bracket, hook it on at the top and tight-
en the fastening screws (tightening torque 4 Nm).
5. Plug in all the connections in accordance with the connector and cable la-
beling. Lock connectors X20 and X21.
6. If exchanging the device resulted in a system modification, the system
configuration of the industrial robot must be configured using WorkVisual.
Fig. 11-14: KPP fastening

KR C4; KR C4 CK
1 Allen screws 3 Support bracket

2 Rear panel of cabinet
11.6.2 Exchanging the KUKA Servo Pack

troller has been shut down, the heat sink surface temper-
atures are likely to be high and could result in burn injuries. Protective gloves
must be worn.



switched off:
 the KPP
 the KSPs
Connections
Fig. 11-15: KSP connection with amplifiers for 3 axes

2 X20 Drive bus OUT

11 Repair

4 X5 DC link OUT
5 X6 DC link IN
7 X21 Drive bus IN
Procedure 1. Unlock connectors X20 and X21 of the data cables. Unplug all connections
to the KSP.

Fig. 11-16: Unlocking connectors X20 and X21
1 Connector unlocked 3 Connector X21 plugged in and

locked
2 Connector locked 4 Connector X20 plugged in and
unlocked
2. Slacken the Allen screws.
The KSP weighs approx. 10 kg. When removing or in-

stalling the KSP, care must be taken to avoid injury by
crushing. Protective gloves must be worn.
3. Lift the KSP slightly, tilt the top forwards and lift the KSP out of the support
bracket.
4. Insert the new KSP into the support bracket, hook it on at the top and tight-
en the fastening screws (tightening torque 4 Nm).
beling. Lock connectors X20 and X21.

KR C4; KR C4 CK
6. If exchanging the device resulted in a system modification, the system

configuration of the industrial robot must be configured using WorkVisual.
Fig. 11-17: KSP fastening
1 Allen screws 3 Support bracket

2 Rear panel of cabinet
11.6.3 Exchanging the Cabinet Control Unit



switched off:
 the KPP
 the KSPs

11 Repair
Connections
Fig. 11-18: Connections on the CCU
Con-
Item Description
nector
1 X14 External fan connection
2 X308 External power supply, safety circuit
3 X1700 Board connection
4 X306 smartPAD power supply
5 X302 SIB power supply
6 X3 KPP1 power supply
7 X29 EDS connection, memory card
8 X30 Ballast resistor temperature monitoring
9 X309 Main contactor 1 (HSn, HSRn)
10 X312 Main contactor 2 (HSn, HSRn)
11 X310 Spare (safe input 2/3, safe output 2/3)
12 X48 Safety Interface Board SIB (orange)
13 X31 Controller bus, KPC (blue)
14 X32 Controller bus, KPP (white)
15 X311 Safe inputs, ZSE1, ZSE2; NHS (jumper plug)
16 X28 Mastering test
17 X43 KUKA Service Interface (KSI) (green)
18 X42 KUKA Operator Panel Interface smartPAD (yellow)
19 X41 KUKA System Bus, KPC (red)
20 X44 EtherCAT Interface (KUKA Extension Bus) (red)
21 X47 Spare (yellow)
22 X46 KUKA System Bus, RoboTeam (green)
23 X45 KUKA System Bus, RoboTeam (orange)
24 X34 Controller bus, RDC (blue)
25 X33 Controller bus, spare (white)
26 X25 Fast Measurement inputs 7 ... 8
27 X23 Fast Measurement inputs 1 ... 6
28 X11 Alarm contact for main switch

KR C4; KR C4 CK
Con-
Item Description
nector
29 X26 Thermostatic switch for transformer
30 X27 Alarm contact for cooling unit
31 X5 KPP2 power supply
32 X22 Options power supply
33 X4 KPC, KPP, internal fan power supply
34 X307 CSP power supply
35 X12 USB
36 X15 Internal cabinet fan (optional)
37 X1 Infeed from low-voltage power supply
38 X301 24 V without battery backup (F301)
39 X6 24 V without battery backup (F6)
40 X305 Battery
41 X21 RDC power supply
Procedure 1. Unlock the data cable connectors. Unplug all connections to the CCU.

Fig. 11-19: Unlocking the data cable connectors

locked
2 Connector locked
2. Remove the screw on the fastening plate and pull the plate with the CCU
out of the tab slots.
3. Check the new CCU for mechanical damage. Insert the fastening plate
with the CCU into the tab slots and screw it firmly in place.
beling. Lock the data cable connectors.

11 Repair
Fig. 11-20: CCU fastening
1 Tabs
2 Fastening screw
11.6.4 Exchanging the Safety Interface Board



switched off:
 the KPP
 the KSPs

KR C4; KR C4 CK
Standard connec-
tions
Fig. 11-21: Standard SIB connections
Con-
Item Description
nector
1 X250 SIB power supply
2 X251 Power supply for additional components
3 X252 Safe outputs
4 X253 Safe inputs
5 X254 Safe inputs
6 X258 KUKA System Bus IN
7 X259 KUKA System Bus OUT
Extended
connections
Fig. 11-22: Extended SIB connections

11 Repair
Con-
Item Description
nector
1 X260 Extended SIB power supply
2 X261 Power supply for additional components
3 X264 Safe outputs 1 and 4
4 X266 Safe outputs 5 to 8
5 X262 Safe inputs
6 X263 Safe inputs
7 X267 Safe inputs
8 X268 KUKA System Bus IN
9 X269 KUKA System Bus OUT
Procedure 1. Unlock the data cable connector of the SIB. Unplug all connections to the
SIB.

Fig. 11-23: Unlocking the data cable connectors

locked
2 Connector locked
2. Remove the screw on the fastening plate and pull the plate with the SIB
out of the tab slots.
3. Check the new SIB for mechanical damage. Insert the fastening plate with
the SIB into the tab slots and screw it firmly in place.
beling. Lock the data cable connectors.
5. If exchanging the SIB resulted in a system modification, the system con-
figuration of the industrial robot must be configured using WorkVisual.

KR C4; KR C4 CK
Fig. 11-24: SIB with fastening plate
1 Fastening screw
2 Tabs
11.6.5 Exchanging the Resolver Digital Converter

Connections
Fig. 11-25: Overview of RDC connections

11 Repair
Con-
Item Description
nector
1 X1 Resolver connection, axis 1
9 X13 EDS connection, memory card, RDC
10 X20 EMD
11 X19 KCB OUT
12 X18 KCB IN
13 X17 EMD power supply
14 X15 Power supply IN
15 X16 Power supply OUT (next KCB device)
Procedure 1. Remove the screws from the lid of the RDC box.
Fig. 11-26: RDC box connections
1 Union for 2 external axis control cables X7 and X8

2 Bolt for ground conductor connection
3 Data cable X31
4 EMD connection X32
5 Cable inlet for resolver connections X1-X6
2. Carefully disconnect all cables and bend them out of the way to the sides.
3. Carefully unplug the EDS connection.
The EDS memory is not removed and remains in the RDC box when
the RDC is exchanged.
4. Remove the fastening screws of the RDC module.

KR C4; KR C4 CK
Fig. 11-27: RDC fastening
1 Fastening the RDC module: M6x10

Tightening torque: 2.0 Nm
2 Fastening the EDS: M2.5 plastic nuts
Tightening torque: 0.1 Ncm
5. Carefully remove the RDC module from the RDC box without tilting it.
6. Insert and fasten the new RDC module.
If an RDC cool was installed, an RDC cool must be installed here as

well.
7. Connect all cables.

8. Plug in the EDS connection.
9. Close the lid of the RDC box and screw it firmly in place.
11.7 Exchanging the batteries
The procedure for exchanging the batteries depends on the variant:
Variant Information
Batteries inside cabinet, behind (>>> 11.7.1 "Exchanging the bat-
cooling duct teries behind the cooling duct"
Page 158)
Batteries in cabinet door (>>> 11.7.2 "Exchanging the bat-
teries in the cabinet door"
Page 161)
11.7.1 Exchanging the batteries behind the cooling duct
Precondition  Robot controller is shut down.

 The robot controller is switched off and secured to prevent unauthorized
persons from switching it on again.


11 Repair
Procedure 1. Shut down the robot controller by means of the main menu item Shut-
down. [Further information is contained in the operating and programming
instructions for the KUKA System Software.]
2. Turn off the robot controller and take measures to prevent it from being
turned on again unintentionally.
3. Disconnect the power cable from the supply.

4. Remove the fastening screws of the cooling duct with a 7 mm socket

wrench. Lift the cooling duct out vertically.
Fig. 11-28: Removing the cooling duct
1 Cooling duct fastening screws

2 Batteries
3 Cooling duct
5. Unplug the battery connection cables.
A short-circuit or short to ground at the battery poles

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

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

KR C4; KR C4 CK
Fig. 11-29: Fastening and connections of the batteries
1 Battery connection cables

2 Velcro strip
7. Take out both battery blocks.
The battery blocks must both be exchanged together.
8. Insert the new battery blocks and plug in the battery connection cables.
Fig. 11-30: Battery polarity
Observe the illustrated battery polarity. Installing the bat-

teries in the wrong position or with reversed polarity can
generate a high short-circuit current and trip the higher-level fuse.
9. Fasten the battery blocks with the Velcro strip.

10. Install the cooling duct and screw it firmly in place.
Storage

11 Repair
To prevent exhaustive discharge and thus destruction of

the batteries, the batteries must be recharged at regular
intervals according to the storage temperature.
If the storage temperature is +20 °C or lower, the batteries must be re-
charged every 9 months.
11.7.2 Exchanging the batteries in the cabinet door


Procedure 1. Unplug the battery connection cables.
A short-circuit or short to ground at the battery poles

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

trip the higher-level fuse. The batteries have no fuse of
their own. It must be ensured that no short-circuit or short to ground is caused
at the battery poles.
2. Remove both battery blocks from the battery holder in the cabinet door.
The battery blocks must both be exchanged together.

KR C4; KR C4 CK
Fig. 11-31: Battery fastening
3. Insert the new battery blocks and plug in the battery connection cables.
Fig. 11-32: Battery polarity
Observe the illustrated battery polarity. Installing the bat-

teries in the wrong position or with reversed polarity can
generate a high short-circuit current and trip the higher-level fuse.
11.8 Exchanging the low-voltage power supply unit


Procedure 1. Remove the rear panel.

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

11 Repair
Fig. 11-33: Low-voltage power supply
1 Power supply connector X2 4 Fastening screws

2 CCU power infeed connector 5 Low-voltage power supply unit
X1 removed
3 XPE connector
5. Insert and fasten the new low-voltage power supply unit.

6. Plug in the connectors; insert and fasten the rear panel.
11.9 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.
Procedure 1. Remove the foam ring.

2. Exchange the filter insert.
3. Insert the foam ring so that it is flush with the pressure relief plug.

KR C4; KR C4 CK
Fig. 11-34: Exchanging the pressure relief plug
1 Pressure relief plug 3 Foam ring

2 Filter insert
11.10 Checking and exchanging the ballast resistors

troller has been shut down, the surface temperatures are
likely to be high and could result in burn injuries. Protective gloves must be
worn.



switched off:
 the KPP
 the KSPs
Description Two different variants of ballast resistors can be installed:

11 Repair
Fig. 11-35: Variants of ballast resistors
Ite Designation
m
1 2 ballast resistors of 22 Ω each
2 4 ballast resistors of 44 Ω each
Procedure 1. Measure the resistance at KPP G1 or KPP G11 with a multimeter at con-
nector X7:
The following values must be complied with:
Measuring
Variant Resistance
point
2 ballast resistors of 22 Ω each X7.1 to X7.3 11 Ω (±10%)
X7.2 to X7.4 11 Ω (±10%)
4 ballast resistors of 44 Ω each X7.1 to X7.3 11 Ω (±10%)
X7.2 to X7.4 11 Ω (±10%)
2. Check the cable:

 Cross-connection of individual wires
 Short-circuit of individual wires with the ground conductor
 Correct wiring in accordance with circuit diagram
If the resistance values are not observed and the cables are OK, exchange
the ballast resistor.
3. Remove the rear panel of the robot controller.
4. Unplug the connecting cables from the ballast resistors.
5. Loosen the fastening screws.

KR C4; KR C4 CK
Fig. 11-36: Ballast resistor connections
1 Fastening screws
2 Connections
3 KPP
6. Remove the ballast resistor.

7. Insert the new ballast resistor and fasten.
8. Push on the connecting cables, paying attention to the correct polarity.
9. Install the rear panel.
11.11 Exchanging the mains filter

Procedure 1. Depending on the cabinet version: Release switching element of main

switch.
2. Unscrew the 4 screws of the main switch and pull off.

11 Repair
Fig. 11-37: Removing the main switch
1 Switching element
2 Threads for fastening screws
3. Unscrew the nut on the inside of the control cabinet with a 7 mm socket
wrench.
Fig. 11-38: Nut on mains filter side panel, bottom
1 Fastening bolt
4. Depending on the version:

Tilt the side panel approx. 45° to the left and unhook it towards the front.

KR C4; KR C4 CK
Fig. 11-39: Tilting the side panel
1 Side panel angled
Unscrew the side panel fastening screws and take off the side panel.
Fig. 11-40: Removing the side panel
1 Fastening screws
5. Release the wire holder and remove the supply cable.

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

11 Repair
Fig. 11-41: Unscrewing the cables
1 Cable wires (3x)

2 Fastening nut
7. Insert the new mains filter and fasten.

8. Connect the wire ends.
9. Insert and close the side panel and fasten it with a nut on the threaded bolt.
10. Install the main switch.
11. Carry out a function test.
11.12 Installing the KUKA System Software (KSS)
Further information is contained in the operating and programming in-

structions for the KUKA System Software (KSS).

KR C4; KR C4 CK

12 Troubleshooting
12
2
Troubleshooting
T
12.1 Cabinet Control Unit LED display

s
Overview
t
Fig. 12-1: CCU LED display
Item Designation Color Description Remedy

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

KR C4; KR C4 CK

4 STAS1 Orange Off = no supply voltage  Check fuse F17.3
Safety node A
CCU module
state
phase
Flashing = fault code (inter- Check cabling at X309,
nal) X310, X312. For test pur-
poses, disconnect the
cables at X309, X310, X312
and switch the controller off
and back on again. If the
error recurs, exchange the
module.
5 FSoE Green Off = not active -
Safety proto- On = operational -
col of the Flashing = fault code (inter- -
EtherCat con- nal)
nection
6 27 V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V)
Voltage, main
power supply On = power supply present -
unit, without
battery
backup
7 PS1 Green Off = no supply voltage  Check infeed at X1 (rat-
present ed voltage 27.1 V)
Voltage,
Power Sup-  Drive bus switched off
ply 1 (short (BusPowerOff state)
battery On = power supply present -
backup)
8 PS2 Green Off = no supply voltage  Check infeed at X1.
present  Controller in Sleep state
Voltage,
Power Sup- On = power supply present -
ply 2 (medium
battery
backup)
9 PS3 Green Off = no supply voltage Check infeed at X1.
present
Voltage,
Power Sup- On = power supply present -
ply 3 (long
battery
backup)

12 Troubleshooting

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

KR C4; KR C4 CK

17 PWR/5V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V)
Power supply
for PMB Flashing at 1 Hz = normal -
state
phase
Flashing = fault code (inter- -
nal)
18 STA2 Orange Off = no supply voltage  Check infeed at X1
FPGA node
CCU module
state
phase
nal)
19 RUN SION Green On = operational (normal -
state)
EtherCat
Safety nodes Off = Init (after switching on) -
Flashing at 2.5 Hz = Pre-Op -
(intermediate state on
startup)
Single signal = Safe Op -
Flashing at 10 Hz = boot (for -
firmware update)
20 RUN CIB Green On = operational (normal -
state)
EtherCat
ATμC I/O Off = Init (after switching on) -
node Flashing at 2.5 Hz = Pre-Op -
startup)
10 Hz = boot (for firmware -
update)

12 Troubleshooting
12.2 Cabinet Control Unit fusing
Overview
Fig. 12-2: Arrangement of the fuses
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.
Item Designation Description Fusing

1 F17.1 Contactor outputs 1 … 4 CCU 5A
2 F17.2 CCU inputs 2A
3 F17.4 CCU safe inputs 2A
4 F17.3 CCU logic 2A
5 F306 smartPAD power supply 2A
6 F302 SIB power supply 5A
7 F3.2 KPP1 logic with battery backup 7.5 A
8 F3.1 KPP1 brakes without battery 15 A
backup

KR C4; KR C4 CK

9 F5.2 KPP2 logic without battery 7.5 A
backup/switch
backup
11 F22 Options power supply with bat- 7.5 A
tery backup
12 F4.1 KPC with battery backup 10 A
13 F4.2 KPC fan/internal fan with bat- 2A
tery backup
14 F307 CSP power supply 2A
15 F21 RDC power supply 2A
16 F305 Battery infeed 15 A
17 F6 24 V without battery backup 7.5 A
US1 (optional)
18 F301 24 V without battery backup, 10 A
spare, US2
19 F15 Internal fan (optional) 2A
20 F14 External fan 7.5 A
21 F308 Internal power supply, external 7.5 A
infeed with battery backup
12.3 Cabinet Control Unit fusing (optional)
Overview
Fig. 12-3: Arrangement of the fuses
The fuse ratings printed on the board must be observed.

12 Troubleshooting

1 F306 smartPAD power supply 2A
2 F302 SIB power supply 5A
backup
backup
5 F4.1 KPC with battery backup 10 A
6 F307 CSP power supply 2A
7 F4.2 KPC fan/internal fan with bat- 2A
tery backup
8 F22 Options power supply with bat- 7.5 A
tery backup
9 F5.2 KPP2 logic without battery 7.5 A
backup/switch
10 F3.2 KPP1 logic with battery backup 7.5 A
11 F17.2 CCU inputs 2A
12 F17.4 CCU safe inputs 2A
13 F17.1 Contactor outputs 1 … 4 CCU 5A
14 F17.3 CCU logic 2A
15 F14 External fan 7.5 A
16 F6 24 V without battery backup 7.5 A
US1 (optional)
17 F21 RDC power supply 2A
18 F305 Battery infeed 15 A
19 F301 24 V without battery backup, 10 A
spare, US2
20 F15 Internal fan (optional) 2A
21 F308 Internal power supply, external 7.5 A
infeed with battery backup
12.4 Resolver Digital Converter LED display
Overview
Fig. 12-4: RDC LED display

KR C4; KR C4 CK
Item Designation Color Description

1 STA3 Yellow  Off = fault
Motor temperature micro-  Flashing at 1 Hz = normal state
controller  Flashing = fault code (internal)
2 RUN Green  Off = Init
EtherCAT AT bus  On = normal state
 Flashing at 2.5 Hz = Pre-Op
 Single signal = Safe Op
 Flashing = fault code (internal)
 Flashing at 10 Hz = boot
3 L/A1 Green  Off = no physical connection. Network
cable not plugged in.
Input of the KCB (X18)
 On = network cable plugged in
 Flashing = data traffic on the line
Output of the KCB (X19)
 On = network cable plugged in
Output of the KCB to the
EMD (X20)  On = network cable plugged in
VMT microcontroller  Flashing at 1 Hz = normal state
7 PWR/3.3V Green  Off = no power
RDC power supply  On = power supply connected
8 FSoE Green  Off = not active
Safety protocol of the  On = operational
EtherCat connection  Flashing = fault code (internal)
FPGA B integrated circuit  Flashing at 1 Hz = normal state
FPGA A integrated circuit  Flashing at 1 Hz = normal state
Configuration microcon-  Flashing at 1 Hz = normal state
troller  Flashing = fault code (internal)

12 Troubleshooting
12.5 Controller System Panel LED display
Overview
Fig. 12-5
Item Designation Description

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

KR C4; KR C4 CK
Controller state
Display Description State
LED1 flashes slowly Controller boots
LED2...LED6 = off
Main switch = on
LED1 flashes slowly HMI not yet loaded
and/or RTS not "RUN-
LED2...LED6 = off
NING"
Main switch = on
PM service started
LED1 = on SM in "Running" state,
HMI and Cross run-
LED3 = any
ning
LED2; LED4...LED6 =
off
Booting completed, no
error
LED1 = on Controller does not yet
shut down
LED3 = any
LED2; LED4...LED6 =
off
Main switch = off
Powerfail timeout not
yet occurred
LED1 flashes slowly Controller shuts down
LED2...LED6 = off
Main switch = off
Powerfail timeout has
occurred
LED1 flashes slowly Controller shuts down
LED2...LED6 = off
SoftPowerDown
CSP test
Display Description
If all LEDs light up for 3 s after the CSP is switched on,
it is working correctly
Automatic mode
Display Description
LED1 = on
LED3 = on
Controller is in Automatic mode
LED1 = on
Controller is not in Automatic mode

12 Troubleshooting
Sleep mode
Display Description
LED2 flashes slowly
Controller is in Sleep mode.
LED1 flashes slowly
Controller is coming out of Sleep mode.
ProfiNet ping
Display Description
LED1 = on
LED4 flashes slowly
LED5 flashes slowly
LED6 flashes slowly
ProfiNet ping is being executed
Maintenance
Display Description
LED1 = on
LED4 flashes slowly
LED2; LED3; LED5; LED6 = off
Maintenance mode active (robot controller mainte-
nance due)
12.5.1 Controller System Panel LED error display
Error states
Display Description Remedy

LED1 flashes slowly  Check the
HDD/SSD
LED4 = on
 Check the USB
Problem with boot stick
device or BIOS error
 Exchange the PC
LED1 flashes slowly  Exchange the hard
drive
LED5 = on
 Reload the image
Timeout booting Win-
dows or starting the
PMS
LED1 flashes slowly  Reload the image
LED6 = on  Run setup
Timeout waiting for

RTS “RUNNING”
LED1 flashes slowly -
Timeout waiting for
HMI Ready
12.6 Control PC interfaces
Motherboards The following motherboard variants can be installed in the control PC:

KR C4; KR C4 CK
 D2608-K
 D3076-K
 D3236-K
12.6.1 LAN Onboard LED display on motherboard D2608-K
Overview
Fig. 12-6: LAN Onboard LED display

1 Activity/Link Green  Off = no connection
 On = connection established
 Flashing = connection active
2 Speed Yel-  Off = 10 Mb
low/gre  Green = 100 Mb
en
 Yellow = 1000 Mb
Overview

12 Troubleshooting

en
Overview

en

KR C4; KR C4 CK
12.7 Safety Interface Board LED display
Standard
Fig. 12-9: Standard SIB LED display

2 L/A Green tion
not plugged in.
the line
3 PWR_3V3 Green Off = no supply voltage  Check fuse F302
Power for the
SIB ent
4 RUN Green On = operational (normal -
state)
EtherCat
startup)
firmware update)

12 Troubleshooting

5 STAS2 Orange Off = no supply voltage  Check fuse F302
present  If the LED PWR_3V3
Safety node B
SIB board
state
phase
nal)
EtherCat con- nal)
nection
Safety node A
SIB board
state
phase
nal)
8 PWRS 3.3V Green On = supply voltage present -
Off = no supply voltage  Check fuse F302
SIB board
9 Fuse LED Red On = fuse defective Exchange defective fuse
The LED indi- Off = fuse OK -
cates the sta-
tus of the fuse

KR C4; KR C4 CK
Extended
Fig. 12-10: Extended SIB LED display

1 Fuse LED Red On = fuse defective Exchange defective fuse
The LED indi- Off = fuse OK -
cates the sta-
tus of the fuse
present  If the LED PWR +3V3
Safety node A
SIB board
state
phase
nal)
EtherCat con- nal)
nection
4 PWRS_+3V3 Green On = supply voltage present -
V Off = no supply voltage  Check fuse F302
SIB board

12 Troubleshooting

tion
not plugged in.
the line
Safety node B
SIB board
state
phase
nal)
tion
not plugged in.
the line
8 RUN Green On = operational (normal -
state)
EtherCat
startup)
firmware update)
9 PWR +3V3 Green Off = no supply voltage  Check fuse F260
Power for the
SIB ent
12.8 Safety Interface Board fuses
Semiconductor Every output channel is fitted with self-resetting semiconductor fuses to guard
fuse against short-circuits.
To reset the semiconductor fuse, the following steps are to be carried out:
 Eliminate the cause of the error
 De-energize the semiconductor fuse for 5 s
The semiconductor fuses are not rated for frequent use and should
not be tripped intentionally, as this will reduce their service life.

KR C4; KR C4 CK
Standard SIB
Fig. 12-11: Standard SIB fuse

1 F250 Test signal power supply, safe 4A
inputs and relay activation
Extended SIB
Fig. 12-12: Extended SIB fuse

12 Troubleshooting

1 F260 Test signal power supply, safe 4A
inputs and relay activation
12.9 Checking the KUKA Servo Pack
Description The KSP LED display consists of the following LED groups:
 KSP device status
 Axis control
 Communication status
If faults occur during the initialization phase, the middle axis control LEDs
flash. All other LEDs are off. The red axis control LED is lit continuously and
the green axis control LED flashes at 2 to 16 Hz, followed by a pause.
If defective firmware is detected during the initialization phase, the red device
status LED is lit and the green device status LED is dimmed.
Precondition
The robot controller is energized (50-600 V) when it is
switched on. This voltage can cause life-threatening inju-
ries on contact. Work and measurements on the electrical equipment may
only be carried out by specially trained personnel.
Procedure 1. Check communication status LED group.

2. Check KSP device status LED group.
3. Check axis control LED group.
Overview
Fig. 12-13: KSP LED display
1 LED group: axis control 3 LED group: communication

status
2 LED group: KSP device status
Device status
Red LED Green LED Meaning
Off Off No power supply to the control elec-
tronics
On Off Fault in the KSP

KR C4; KR C4 CK

Off Flashing No communication with the control-
ler
Off On Communication with the controller
Axis control
tronics
Axis not present
On Off Fault in the axis
Off Flashing No servo enable
Off On Servo enable
Communication The green communication LEDs indicate the status of the bus connection.
12.10 Checking the KUKA Power Pack
Description The KPP LED display consists of the following LED groups:
 Supply
 KPP device status
 Axis control
 Communication status
If faults occur during the initialization phase, the middle axis control LEDs
flash. All other LEDs are off. The red axis control LED is lit continuously and
the green axis control LED flashes at 2 to 16 Hz, followed by a pause.
If defective firmware is detected during the initialization phase, the red device
status LED is lit and the green device status LED is dimmed.
Precondition
Procedure 1. Check power supply LED group.

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

12 Troubleshooting
Overview
Fig. 12-14: KPP LED display
1 LED group: power supply 3 LED group: communication

status
2 LED group: KPP device status 4 LED group: axis control
Power supply Red LED Green LED Meaning

tronics
On Off Fault in the power supply
Off Flashing Intermediate circuit voltage out of
the permitted range
Off On Intermediate circuit voltage within
the permitted range
Device status Red LED Green LED Meaning

tronics
On Off Fault in the KPP
Off Flashing No communication with the control-
ler
Off On Communication with the controller
Axis control Red LED Green LED Meaning

tronics
Axis not present
On Off Fault in the axis
Off Flashing No servo enable
Off On Servo enable
Communication The green communication LEDs indicate the status of the bus connection:
LED Description
On Connected, no data transfer
Flashing Connected, data transfer
Off No connection

KR C4; KR C4 CK
12.11 Checking the KUKA Power Pack 3
Description The LED display on the KPP indicates the communication status of the bus
connection.
Precondition
Overview
Fig. 12-15: KPP 3x20 A LED display
1 LED group: communication status
Communication The green communication LEDs indicate the status of the bus connection:
LED Description
On Connected, no data transfer
Flashing Connected, data transfer
Off No connection
12.12 KPP and KSP error messages
Description The error messages have corresponding acknowledgement messages.

 In these messages, %1 stands for the device type (KSP or KPP).
 In these messages, %2 stands for the number of the drive or power supply
(KSP or KPP).
 %3 stands for error codes for further differentiation of the cause of the er-
ror.
Error no. Error Cause Remedy

26030 Device state: OK - -
26031 Internal error, The device has  Reinitialize the drive bus:
KPP/KSP (axis) detected an internal Power Off / Power On
error.  Check KPP (see LEDs)

12 Troubleshooting

26032 IxT overload Axis overloaded  During start-up => excessive
error, KPP/KSP Mean continuous cur- load in program
(axis) rent too high  Reinitialize the drive bus:
Power Power Off / Power On
Excessive load  During operation
 Modifications to system
 Check machine
 Temperature influences
 Check trace recording of ax-
is/current
 Adapt program velocity
 Check CBS pressure
 Check gear unit
26033 Ground fault, Power unit overcurrent  Check motor cable
KPP/KSP (axis) (ground fault)  Check motor
 Reinitialize the drive bus:
Power Off / Power On
 Check KSP
 Check KPP
26034 Overcurrent, Fault that briefly results  Check trace recording of ax-
KPP/KSP (axis) in an overcurrent that is/current
exceeds the maximum  Check motor
current of the KPP
 Check motor cable
(short-circuit,…)
 Check KSP
 Check KPP
26035 Intermediate cir- Overvoltage in interme-  Check trace recording of the
cuit voltage too diate circuit during intermediate circuit
high, KPP/KSP operation  Check mains voltage
(axis)
 Check ballast switch
 Excessive load during braking
=> reduce
 Check KSP
 Check KPP
26036 Intermediate cir- Undervoltage in inter-  Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
low, KPP/KSP operation  Check mains voltage
(axis)
 Check intermediate circuit ca-
bling
 Check KSP
 Check KPP charging circuit

KR C4; KR C4 CK

26037 Logic supply volt- Overvoltage in 27 V  Check 27 V supply
age too high, supply  Check power supply to 27 V
KPP/KSP (axis) power supply unit
 Check KSP
 Check KPP
26038 Logic supply volt- Undervoltage in 27 V  Check 27 V supply
age too low, supply  Check power supply to 27 V
 Check battery
 Check KSP
 Check KPP
26039 Device tempera- Overtemperature  Check cabinet fan
ture too high,  Check ambient temperature
KPP/KSP (axis)
 Load in program too high,
check load
 Dirt in cooling circuit => clean
 Check PC fan
 Check KSP
 Check KPP
26040 Heat sink temper- Overtemperature, heat  Check cabinet fan
ature too high, sink  Check ambient temperature
KPP/KSP (axis)
check and reduce load
 Check installation site, ventila-
tion slits and clearance
 Check KSP
 Check KPP
26041 Motor phase fail- Failure of motor phase  Check motor cable
ure, KPP/KSP  Check motor
(axis)
 Check KSP
26042 Communication Communication error  Reinitialize the drive bus:
error, KPP/KSP on the controller bus Power Off / Power On
(axis)  Check EtherCat cabling
 Check EtherCat stack
 Check CCU
 Check KPP
 Check KSP

12 Troubleshooting

26043 Unknown status Software error, Ether- -
flag received, Cat master
KPP/KSP (axis)
26044 Unknown device - -
status, KPP/KSP
(axis)
26045 Hardware fault, The device has  Reinitialize the drive bus:
hardware fault.  Check device (see LEDs)
 Exchange device
26046 Mains phase fail- Failure of mains phase  Check power lead
ure, KPP/KSP  Check KPP cabling
(axis)
 Check KPP
26047 Power supply fail- Failure, supply voltage  Check power lead
ure, KPP/KSP below 300 V  Check KPP cabling
(axis)
 Check KPP
26048 Overvoltage dur- -  Mains voltage too high
ing charging,  Too few capacitors connected
KPP/KSP (axis) (too few modules)
 Check KPP
26050 Fault in brake KPP has detected an  Check ballast resistor
resistor, KPP/KSP error in the ballast cir-  Check cabling between KPP
(axis) cuit and ballast resistor
 Check KPP
26051 Ballast circuit Braking energy perma-  Reduce heavy loads that are
overload, nently too high braked too frequently
KPP/KSP (axis)  Check ballast resistor
 Check cabling between KPP
and ballast resistor
 Check KPP

KR C4; KR C4 CK

26130 Intermediate cir- -  Check intermediate circuit ca-
cuit charging bling
failed, KPP/KSP  Reinitialize the drive bus:
(axis) Power Off / Power On
 Check KSP
 Check KPP
26132 Collective brake Brake cable monitor-  Check brake voltage => fault
fault, KPP/KSP ing device has signaled in all axes
(axis) short-circuit, overload-  Check motor / brake (mea-
ing or break in connec- sure)
tion. / short-circuit /
 Check brake cable / motor ca-
overcurrent / no brake
ble
connected
 Check KSP
12.13 KPP and KSP warning messages
Description The warning messages have corresponding acknowledgement messages.

 In these messages, %1 stands for the device type (KSP or KPP).
 In these messages, %2 stands for the number of the drive or power supply
(KSP or KPP).
 %3 stands for error codes for further differentiation of the cause of the er-
ror.
Error no. Warning Cause Remedy

26102 Device state: OK - -
26103 Internal error, The device has  Reinitialize the drive bus:
error.  Check KPP (see LEDs)
26104 IxT overload Axis overloaded  During start-up => excessive
error, KPP/KSP Mean continuous cur- load in program
(axis) rent too high  Reinitialize the drive bus:
Power Power Off / Power On
Excessive load  During operation
 Modifications to system
 Check machine
 Temperature influences
 Check trace recording of ax-
is/current
 Adapt program velocity
 Check CBS pressure
 Check gear unit
26105 Ground fault, Power unit overcurrent  Check motor cable
KPP/KSP (axis) (ground fault)  Check motor
 Check KSP
 Check KPP

12 Troubleshooting

26106 Overcurrent, Fault that briefly results  Check trace recording of ax-
KPP/KSP (axis) in an overcurrent that is/current
exceeds the maximum  Check motor
current of the KPP
 Check motor cable
(short-circuit,…)
 Check KSP
 Check KPP
26107 Intermediate cir- Overvoltage in interme-  Check trace recording of the
cuit voltage too diate circuit during intermediate circuit
high, KPP/KSP operation  Check mains voltage
(axis)
 Check ballast switch
 Excessive load during braking
=> reduce
 Check KSP
 Check KPP
26108 Intermediate cir- Undervoltage in inter-  Check trace recording of the
cuit voltage too mediate circuit during intermediate circuit
low, KPP/KSP operation  Check mains voltage
(axis)
 Check intermediate circuit ca-
bling
 Check KSP
 Check KPP charging circuit
26109 Logic supply volt- Overvoltage in 27 V  Check 27 V supply
age too high, supply  Check power supply to 27 V
 Check KSP
 Check KPP
26110 Logic supply volt- Undervoltage in 27 V  Check 27 V supply
age too low, supply  Check power supply to 27 V
 Check battery
 Check KSP
 Check KPP

KR C4; KR C4 CK

26111 Device tempera- Overtemperature  Check cabinet fan
ture too high,  Check ambient temperature
KPP/KSP (axis)
check load
 Check PC fan
 Check KSP
 Check KPP
26112 Heat sink temper- Overtemperature, heat  Check cabinet fan
ature too high, sink  Check ambient temperature
KPP/KSP (axis)
check and reduce load
 Check installation site, ventila-
tion slits and clearance
 Check KSP
 Check KPP
26113 Motor phase fail- Failure of motor phase  Check motor cable
ure, KPP/KSP  Check motor
(axis)
 Check KSP
26114 Communication Communication error  Reinitialize the drive bus:
error, KPP/KSP on the controller bus Power Off / Power On
(axis)  Check EtherCat cabling
 Check EtherCat stack
 Check CCU
 Check KPP
 Check KSP
26115 Unknown status Software error, Ether- -
flag received, Cat master
KPP/KSP (axis)
26116 Unknown device - -
status, KPP/KSP
(axis)
26117 Hardware fault, The device has  Reinitialize the drive bus:
hardware fault.  Check device (see LEDs)
 Exchange device
26118 Mains phase fail- Failure of mains phase  Check power lead
ure, KPP/KSP  Check KPP cabling
(axis)
 Check KPP

12 Troubleshooting

26119 Power supply fail- Failure, supply voltage  Check power lead
ure, KPP/KSP below 300V  Check KPP cabling
(axis)
 Check KPP
26120 Overvoltage dur- -  Mains voltage too high
ing charging,  Too few capacitors connected
KPP/KSP (axis) (too few modules)
 Check KPP
 Check KSP, improbable
26122 Fault in brake KPP has detected an  Check ballast resistor
resistor, KPP/KSP error in the ballast cir-  Check cabling between KPP
(axis) cuit and ballast resistor
 Check KPP
26123 Ballast circuit Braking energy perma-  Reduce heavy loads that are
overload, nently too high braked too frequently
KPP/KSP (axis)  Check ballast resistor
 Check cabling between KPP
and ballast resistor
 Check KPP
26131 Intermediate cir- -  Check intermediate circuit ca-
cuit charging bling
failed, KPP/KSP  Reinitialize the drive bus:
(axis) Power Off / Power On
 Check KSP
 Check KPP
26133 Collective brake Brake cable monitor-  Check brake voltage => fault
fault, KPP/KSP ing device has signaled in all axes
(axis) short-circuit, overload-  Check motor / brake (mea-
ing or break in connec- sure)
tion. / short-circuit /
 Check brake cable / motor ca-
overcurrent / no brake
ble
connected
 Check KSP

KR C4; KR C4 CK

13 Decommissioning, storage and dispos...
13 Decommissioning, storage and disposal
13.1 Decommissioning
s
Description This section describes all the work required for decommissioning the robot
controller if the robot controller is to be removed from the system. After decom-
missioning, it is prepared for storage or for transportation to a different loca-
tion.
Following its removal, the robot controller may only be transported with lifting
tackle and a fork lift truck or pallet truck.
Precondition  The removal site must be accessible with a crane or with a fork lift truck for
transportation.
 The crane and fork lift truck have an adequate carrying capacity.
 There is no hazard posed by system components.
Procedure 1. Release and unplug all peripheral connections.

2. Release and unplug the motor cable and control cable connectors.
3. Disconnect the ground conductor.
4. Prepare the robot controller for storage.
13.2 Storage
Precondition If the robot controller is to be put into long-term storage, the following points
must be observed:
 The place of storage must be as dry and dust-free as possible.
 Avoid temperature fluctuations.
 Avoid wind and drafts.
 Avoid condensation.
 Observe and comply with the permissible temperature ranges for storage.
(>>> 4 "Technical data" Page 33)
 Select a storage location in which the packaging materials cannot be dam-
aged.
 Only store the robot controller indoors.
Procedure 1. Clean robot controller. No dirt may remain on or in the robot controller.
2. Inspect the robot controller, both internally and externally, for damage.
3. Remove batteries and store in accordance with the manufacturer’s instruc-
tions.
4. Remove any foreign bodies.
5. Remove any corrosion expertly.
6. Attach all covers to the robot controller and check that the seals are cor-
rectly in place.
7. Seal off electrical connections with suitable covers.
8. Cover the robot controller with plastic film and seal it against dust.
If necessary, add a desiccant beneath the sheeting.
13.3 Disposal
When the robot controller reaches the end of its useful life, it can be disman-
tled, and the materials can be disposed of properly by type.

KR C4; KR C4 CK
The following table provides an overview of the materials used in the robot
controller. Some of the plastic components are marked with a material desig-
nation and must be disposed of accordingly.
As the end user, the customer is legally required to return depleted

batteries. Used batteries can be returned to the vendor or brought to
the designated collection points (e.g. in communal refuse collection
facilities or commercial centers) free of charge. The batteries can also be
sent to the vendor by post.
The following symbols can be found on the batteries:
 Crossed-out garbage can: battery must not be disposed of with ordinary
household refuse.
 Pb: battery contains more than 0.004 lead by weight.

 Cd: battery contains more than 0.002 cadmium by weight.
 Hg: battery contains more than 0.0005 mercury by weight.
Subassembly, com-
Material, designation Note
ponent
Steel Screws and washers, -
robot controller hous-
ing
PUR Cable sheaths -
ETFE Flexible tube -
Copper Electrical cables, wires -
EPDM Seals and covers -
CuZn (gold-plated) Connectors, contacts Dispose of without dis-
mantling
Steel (ST 52-3) Allen screws, washers -
PE Cable straps -
Electrical components Bus modules, boards, Dispose of as electri-
sensors cal scrap without dis-
assembling

14 KUKA Service
14
4
KUKA Service
A
14.1 Requesting support

v
Introduction This documentation provides information on operation and operator control,

and provides assistance with troubleshooting. For further assistance, please
contact your local KUKA subsidiary.
Information The following information is required for processing a support request:

 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 Model and serial number of the controller
 Model and serial number of the energy supply system
 Designation and version of the system software
 Designations and versions of other software components or modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the
software (KRCDiag is not yet available here.)
 Application used
 External axes used
14.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]
Australia KUKA Robotics Australia Pty Ltd

45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
[email protected]
www.kuka-robotics.com.au

KR C4; KR C4 CK
Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be
Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br
Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl
China KUKA Robotics China Co., Ltd.

No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
[email protected]
www.kuka-robotics.com
Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
[email protected]
www.kuka-roboter.de

14 KUKA Service
France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr
India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
[email protected]
www.kuka.in
Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
[email protected]
www.kuka.it
Japan KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
[email protected]
Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

KR C4; KR C4 CK
Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
[email protected]
Malaysia KUKA Robot Automation (M) Sdn Bhd

South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
[email protected]
Mexico KUKA de México S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]
www.kuka-robotics.com/mexico
Norway KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
[email protected]
Austria KUKA Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
[email protected]
www.kuka.at

14 KUKA Service
Poland KUKA Roboter Austria GmbH

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]
Portugal KUKA Robots IBÉRICA, S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
[email protected]
www.kuka.com
Russia KUKA Robotics RUS

Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
[email protected]
www.kuka-robotics.ru
Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]
Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

KR C4; KR C4 CK
Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
[email protected]
www.kuka.es
South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
[email protected]
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
[email protected]
www.kuka-roboter.de
Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
[email protected]

14 KUKA Service
Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]
USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com
UK KUKA Robotics UK Ltd

Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
[email protected]
www.kuka-robotics.co.uk

KR C4; KR C4 CK

Index
Index
Numbers Connection panel 15
2006/42/EC 66 Control PC 15, 17
2014/30/EU 66 Control PC components, exchanging 139
2014/68/EU 66 Control PC, exchanging 139
24 V external power supply 21 Control PC, functions 18
95/16/EC 66 Control unit 34
Controller state 180
A Controller System Panel 15, 20
Accessories 15, 43 Controller System Panel LED display 179
Altitude 34 Controller System Panel LED error display 181
Ambient temperature 33 Cooling circuits 30
ANSI/RIA R.15.06-2012 66 Counterbalancing system 64
Applied norms and regulations 65 CSP 10, 20
Automatic mode 63 CSP LED display 179
Axis limitation, mechanical 54 CSP LED error display 181
Axis range 44 CSP overview 20
Axis range monitoring 54 Customer equipment 31
B D
Ballast resistor, checking 164 Danger zone 45
Ballast resistor, exchanging 164 Data cables 24, 122
Basic data 33 Declaration of conformity 44
Batteries 15, 21 Declaration of incorporation 43, 44
Batteries behind the cooling duct, exchanging Decommissioning 64, 201
158 defective fuses 175, 176, 188
Batteries, exchanging 158 Dimensions of boreholes 39
Batteries, exchanging (cabinet door) 161 Dimensions of robot controller 36
Battery discharge protection, reversing 123 Dimensions, smartPAD holder 38
BR M 10 Disposal 64, 201
Brake defect 57 Documentation, industrial robot 9
Brake release device 55 Drive controller 15
Braking distance 44 Drive power supply 15
Bus devices 21 Dual NIC 10
Dynamic testing 98
C
Cabinet Control Unit 15, 18 E
Cabinet Control Unit fusing, optional 176 EA 11
Cabinet Control Unit LED display 171 EC declaration of conformity 44
Cabinet Control Unit, exchanging 150 EDS 10
Cabinet Control Unit, fusing 175 EDS cool 10
Cabinet cooling 30 Electromagnetic compatibility (EMC) 66
Cabinet Interface Board 18 Electromagnetic compatibility, EMC 69
Cabinet type 33 EMC 10
Cable lengths 35, 71 EMC Directive 44, 66
CCU 10, 18 EMD 10
CCU functions 18 EMERGENCY STOP 128
CCU LED display, overview 171 EMERGENCY STOP device 51, 52, 56
CE mark 44 EMERGENCY STOP devices to X11 96
Charge 21 EMERGENCY STOP wiring example 96
CIB 10, 18 EMERGENCY STOP, external 52, 59
CIP Safety 10 EMERGENCY STOP, local 59
CK 10 EN 60204-1 + A1 67
Cleaning work 63 EN 61000-6-2 66
Configuration of cooling circuit 31 EN 61000-6-4 + A1 66
Connecting cables 15, 43 EN 614-1 + A1 66
Connecting cables, connecting 121 EN ISO 10218-1 66
Connection conditions 70 EN ISO 12100 66
Connection manager 128 EN ISO 13849-1 66

KR C4; KR C4 CK
EN ISO 13849-2 66 Interfaces, motherboard D3076-K 27

EN ISO 13850 66 Interfaces, motherboard D3236-K 28
Enabling device 52, 56 Internal fan, exchange 138
Enabling device, external 53 Introduction 9
Enabling switch 129
Enabling switch, external, X11 95 J
Enabling switches 52, 103 Jog keys 128
Environmental conditions 33 Jog mode 53, 56
Equipotential bonding 33, 71
Error states, CSP 181 K
EtherCAT connection on the CIB 108 KCB 10
Ethernet interface (RJ45), X66 107 KCB devices 22
Ethernet interfaces 99 KEB 10
Ethernet/IP 10 KEB configuration variants 22
Exchanging devices 110, 124, 144 KEB devices 22
Exhaustive discharge, battery 34, 161 Keyboard 128
Extended SIB relay outputs, checking 133 Keyboard key 128
Extended SIB, connections 154 KLI 10
Extended SIB, fuse 188 KONI 10
Extended SIB, LED display 186 KPC 10
External axes 43, 46 KPP 10, 17
External axes 1 and 2 78 KPP and KSP warning messages 196
External axis X7.1 75 KPP error messages 192
External axis X7.2 75 KPP, exchanging 144
External axis X7.3 75 KRL 10
External enabling switch, function 95 KSB 10
External fan, exchange 137 KSB configuration variants 22
External voltage 35, 71 KSB devices 22
KSI 11
F KSP 11, 17
Fan, external, exchange 137 KSP error messages 192
Fan, internal, exchange 138 KSP, exchanging 148
Fans 15 KSS 11
Faults 57 KUKA Customer Support 203
Filter mats 30 KUKA Power Pack 15, 17
Floor mounting 39 KUKA Power Pack, 3x20 A, checking 192
Full-load current 33, 70 KUKA Power Pack, checking 190
Function test 58 KUKA Servo Pack 15, 17
Fuse elements 15 KUKA Servo Pack, checking 189
KUKA smartPAD 34, 45, 127
G KUKA smartPAD cable 24
General safety measures 56 KUKA smartPAD holder (optional) 29
Ground leakage current 33, 70 KUKA smartPAD holder, fastening 72
H L
Handling equipment 115 Labeling 55
Hard drive, exchanging 143 LAN Dual NIC network card, exchanging 142
Hazardous substances 64 LAN Onboard LED display 182, 183
HMI 10 LED group KPP axis control 191
Humidity class 34 LED group KPP communication 191, 192
LED group KPP device status 191
I LED group KPP power supply 191
Identification plate 129 LED group KSP axis control 190
Industrial robot 15, 43 LED group KSP communication 190
Infeed 24 LED group KSP device status 189
Installation, KUKA System Software 169 Liability 43
Intended use 13, 43 Lifting frame 113
Interfaces, connection panel 24 Linear unit 43
Interfaces, control PC 25, 181 Low Voltage Directive 44
Interfaces, discrete 92 Low-voltage power supply 21
Interfaces, motherboard D2608-K 26 Low-voltage power supply unit 15

Index
Low-voltage power supply unit, exchanging 162 Options 15, 43

Overload 57
M Overview of robot controller 15
Machine data 59 Overview of the industrial robot 15
Machinery Directive 44, 66 Overview, interfaces 72
Mains filter 21 Overview, start-up 119
Mains filter, exchanging 166
Mains frequency 33, 70 P
Mains-side fusing 33, 70 Palletizing robot, connector pin allocation X7.1
Maintenance 63, 131, 181 82
Maintenance symbols 131 Palletizing robot, connector pin allocation X7.1
Manipulator 11, 15, 43, 45 and X7.2 82
Manual mode 62 Palletizing robot, external axes 1 and 2 82
Material designation 202 Palletizing robot, external axis 1 82
Mechanical end stops 54 Panic position 52
Minimum clearances, robot controller 37 PC fan, exchanging 140
Mode selector switch 128 PE cables 24
Monitoring, physical safeguards 50 PE equipotential bonding, connecting 122
Monitoring, velocity 53 PE, equipotential bonding 108
Motherboard battery, exchange 142 PELV 11
Motherboard D2608-K 26 PELV power supply unit 35, 71
Motherboard D3076-K 27, 28 Performance level 110
Motherboard D3236-K 28, 29 Performance Level 48
Motherboard, exchanging 142 Peripheral cables 24
Motherboards 25, 181 Peripheral contactor 61
Motor cables 24 Permissible tolerance of rated voltage 33, 70
Motor connector X20 76, 79, 80 Personnel 46
Motor connector X20.1 80 PFH values 110
Motor connector X20.4 80 PL 110
Motor connector X7.1 77, 82 Planning 69
Motor connector X8 79 Plant integrator 46
Motor connector X8, palletizing robot 79 Plates and labels 39
Motor connector X81 81, 83 PMB 18
Motor connector X82 81 Positioner 43
Motor connector Xxx 75 Power cable 24
Motor connector, X20.1 77 Power failure 21
Motor connector, X20.4 77 Power Management Board 18
Motor connectors X7.1 and X7.2 78 Power supply connection X1 Harting connector
Motor connectors X7.1, X7.2, X7.3X7.1, X7.2, 91, 123
X7.3, motor connectors 78 Power supply connection, technical data 33, 70
Motor connectors X7.1...X7.3 87 Power supply with battery backup 19
Motor connectors X7.1...X7.4 88 Power supply without battery backup 19
Motor connectors X7.1...X7.5 88 Power switched off 21
Motor connectors X7.1...X7.6 89 Pressure Equipment Directive 64, 66
Motor connectors X7.1...X7.7 90 Pressure relief plug, exchanging 163
Motor connectors X7.1...X7.8 90 Preventive maintenance work 63
Motor connectors X81, X7.1 84 Procurement of spare parts 135
Motor connectors X81, X7.1 and X7.2 84 Product description 15
Motor connectors X81, X7.1...X7.3 85 Protection rating 33
Motor connectors X81, X7.1...X7.4 86 Protective equipment 53
Motor interfaces 74 Purpose 13
Multiple connector X81 82
Q
N QBS 11
NA 11
R
O Rated supply voltage 33, 70
Operation 127 RDC 11
Operator 47 RDC cool 11
Operator safety 48, 50, 56 RDC functions 20
Operator safety acknowledgement 110 RDC LED display, overview 177

KR C4; KR C4 CK
Reaction distance 44 Simulation 62

Recommissioning 58, 119 Single connectors X7.1 to X7.4 82
Release device 55 Single connectors X7.1 to X7.8 87
Repair 63, 135 Single point of control 64
Resolver cable, length difference 35, 71 SION 11
Resolver Digital Converter 19 Sleep mode, CSP 181
Resolver Digital Converter, exchanging 156 Slot assignment, motherboard D2608-K 26
Resolver Digital Converter, LED display 177 Slot assignment, motherboard D3076-K 28
Robot controller 15, 43 Slot assignment, motherboard D3236 29
Robot controller stacked 70 smartPAD 45, 57, 127
Robot controller, cleaning 134 smartPAD cable extensions 35, 71
Robot controller, installing 120 smartPAD holder, fastening 122
RTS 11 smartPAD, plugging in 122
Software 15, 43
S Software limit switches 54, 56
Safe operational stop 45, 53 SOP 11
Safeguard to X11 96 Sound level 33
Safeguards, external 55 Space for integration of customer options 31
Safely isolated 35, 71 Space Mouse 128
SafeOperation via Ethernet safety interface 104 SPOC 64
Safety 43 SPS (PLC) 11
Safety controller 49 SRM 11
Safety functions 48, 56 SSB 11
Safety functions, Ethernet safety interface 99 Standard SIB, connections 154
Safety functions, overview 48 Standard SIB, fuses 188
Safety gate, wiring example 96 Start backwards key 128
Safety instructions 9 Start key 128, 129
Safety Interface Board 15, 19, 35 Start-up 58, 119
Safety Interface Board, exchanging 153 Start-up mode 60, 125
Safety Interface Board, fuses 187 Start-up overview 119
Safety Interface Board, LED display 184 Status keys 128
Safety interface X11, description 92 STOP 0 44, 46
Safety of machinery 66, 67 STOP 1 44, 46
Safety options 45 STOP 2 44, 46
Safety options, interfaces 92 Stop category 0 46
Safety STOP 0 45 Stop category 1 46
Safety STOP 1 45 Stop category 2 46
Safety STOP 2 45 STOP key 128
Safety STOP 0 45 Stop reactions 48
Safety STOP 1 45 Stopping distance 44, 47
Safety STOP 2 45 Storage 64, 201
Safety stop, external 53 Storage of batteries 160
Safety zone 45, 47 Support request 203
Safety, general 43 Swing range for cabinet door 38
SATA connections 11 Switching on the robot controller 126
Selecting the operating mode 48, 49 System configuration, modifying 110, 124, 144
Semiconductor fuse 187 System integrator 44, 46, 47
Service life 45
Service, KUKA Roboter GmbH 203 T
SG FC 11 T1 46
SIB 11, 19, 35 T2 46
SIB description 19 Target group 13
SIB functions 19 Teach pendant 15, 43
SIB inputs 36 Technical data 33
SIB LED display, overview 184 Technology cabinet 39
SIB outputs 35 Terms used 10
SIB relay outputs, checking 133 Terms used, safety 44
SIB wiring 92 Test output A 92, 95
SIB, safe input 97 Test output B 93, 95
SIB, safe output 98 Touch screen 127
Signal “Peri enabled” 94 Trademarks 9

Index
Training 13 X81, 4 axes 81, 83

Transportation 58, 113 X81, motor connector 81, 83
Transportation by fork lift truck 114 X81, X7.1 and X7.2, 6 axes 84
Transportation using fork slots 115 X81, X7.1 and X7.2, motor connectors 84
Transportation with standard cabinet base 115 X81, X7.1, 5 axes 84
Transportation with transformer 115 X81, X7.1, motor connectors 84
Transportation, lifting tackle 113 X81, X7.1...X7.3, 7 axes 85
Transportation, pallet truck 116 X81, X7.1...X7.3, motor connectors 85
Transportation, roller set 117 X81, X7.1...X7.4, 8 axes 86
Troubleshooting 171 X81, X7.1...X7.4, motor connectors 86
Turn-tilt table 43 X82, 8 axes 81
X82, motor connector 81
U
US1 11
US2 11, 61
USB 11
USB connection 129
Use, contrary to intended use 43
Use, improper 43
User 45, 46
V
Velocity monitoring 53
Vibration resistance 34
W
Warnings 9
Weight 33
Wiring example X11 136
Workspace 44, 47
X
X11, configuring 124
X11, contact diagram 92
X11, enabling switch 95
X20, motor connector 76, 79, 80
X20, palletizing robot, 4 axes 79
X20, palletizing robot, 5 axes 80
X20.1, heavy-duty robot, 5 axes 80
X20.1, motor connector 77, 80
X20.4, heavy-duty robot, 5 axes 80
X20.4, motor connector 77, 80
X66, Ethernet interface 107
X7.1, external axis 82
X7.1, motor connector 77, 78, 82
X7.1...X7.3, 3 axes 87
X7.1...X7.3, motor connectors 87
X7.1...X7.4, 4 axes 88
X7.1...X7.5, 5 axes 88
X7.1...X7.6, 6 axes 89
X7.1...X7.7, 7 axes 90
X7.1...X7.8, 8 axes 90
X7.2, external axis 82
X7.2, motor connector 78
X8, motor connector 79
X81, 3 axes 83

KR C4; KR C4 CK

KR C4; KR C4 CK

KRC4-Operating Instructions en

Uploaded by

Copyright:

Available Formats

KRC4-Operating Instructions en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

KRC4-Operating Instructions en

Uploaded by

Copyright:

Available Formats

Controller KUKA Roboter GmbH

Publication: Pub BA KR C4 GI (PDF) en

2 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

3 Product description ..................................................................................... 15

4 Technical data .............................................................................................. 33

Issued: 05.10.2016 Version: BA KR C4 GI V16 3 / 217

4.9 Plates and labels ....................................................................................................... 39

4 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

Issued: 05.10.2016 Version: BA KR C4 GI V16 5 / 217

6.10 EtherCAT connection on the CIB .............................................................................. 108

7 Transportation ............................................................................................. 113

8 Start-up and recommissioning ................................................................... 119

9 Operation ...................................................................................................... 127

10 Maintenance ................................................................................................. 131

11 Repair ............................................................................................................ 135

6 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

11.5.6 Exchanging the hard drive .................................................................................... 143

12 Troubleshooting .......................................................................................... 171

13 Decommissioning, storage and disposal .................................................. 201

14 KUKA Service .............................................................................................. 203

Index ............................................................................................................. 211

Issued: 05.10.2016 Version: BA KR C4 GI V16 7 / 217

8 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

1.1 Industrial robot documentation

The industrial robot documentation consists of the following parts:

1.2 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

These warnings mean that death or severe injuries may

These warnings mean that minor injuries may occur, if

These warnings mean that damage to property may oc-

These warnings contain references to safety-relevant information or

This warning draws attention to procedures which serve to prevent or remedy

Procedures marked with this warning must be followed

Tip to make your work easier or reference to further information.

 Windows is a trademark of Microsoft Corporation.

 EtherCAT® is a registered trademark and patented technol-

Issued: 05.10.2016 Version: BA KR C4 GI V16 9 / 217

 CIP Safety® is a trademark of ODVA.

1.4 Terms used

10 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

Issued: 05.10.2016 Version: BA KR C4 GI V16 11 / 217

12 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

2.1 Target group

For optimal use of our products, we recommend that our customers

2.2 Intended use

Issued: 05.10.2016 Version: BA KR C4 GI V16 13 / 217

14 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16

The industrial robot consists of the following components:

Fig. 3-1: Example of an industrial robot

1 Manipulator 3 KUKA smartPAD

3.2 Overview of the robot controller

The robot controller consists of the following components:

Issued: 05.10.2016 Version: BA KR C4 GI V16 15 / 217

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

1 Mains filter 8 Brake filter

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

1 KSP/KPP heat sink 4 External fan

16 / 217 Issued: 05.10.2016 Version: BA KR C4 GI V16