Kuka KR C4 compact Manual
Mainos
Mainos
Controller
KR C4 compact
Specification
KUKA Deutschland GmbH
Issued: 20.04.2018
Version: Spez KR C4 compact V10
KR C4 com-
pact
KR C4 compact
Specification
KUKA Deutschland GmbH
Issued: 20.04.2018
Version: Spez KR C4 compact V10
KR C4 com-
pact
KR C4 compact
2 / 93 Issued: 20.04.2018 Version: Spez KR C4 compact V10
© Copyright 2018
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and 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.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub Spez KR C4 compact (PDF) en
Book structure: Spez KR C4 compact V8.1
Version: Spez KR C4 compact V10
2 / 93 Issued: 20.04.2018 Version: Spez KR C4 compact V10
© Copyright 2018
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and 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.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub Spez KR C4 compact (PDF) en
Book structure: Spez KR C4 compact V8.1
Version: Spez KR C4 compact V10
3 / 93Issued: 20.04.2018 Version: Spez KR C4 compact V10
Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Trademarks ................................................................................................................ 7
1.4 Terms used ................................................................................................................ 8
2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9
3 Product description ..................................................................................... 11
3.1 Description of the industrial robot .............................................................................. 11
3.2 Overview of the robot controller ................................................................................. 11
3.3 Control box ................................................................................................................. 12
3.3.1 Control PC ............................................................................................................ 12
3.3.2 Cabinet Control Unit, Small Robot ........................................................................ 13
3.3.3 Low-voltage power supply unit ............................................................................. 14
3.3.4 Batteries ................................................................................................................ 14
3.3.5 Mains filter ............................................................................................................ 14
3.4 Drive box (Drive Configuration (DC)) ......................................................................... 14
3.5 Description of interfaces ............................................................................................ 15
3.5.1 Control PC interfaces ............................................................................................ 16
3.5.1.1 Motherboard D3076-K PC interfaces ............................................................... 17
3.5.1.2 Motherboard D3236-K PC interfaces ............................................................... 18
3.5.1.3 Motherboard D3445-K PC interfaces ............................................................... 19
3.6 Cooling ....................................................................................................................... 20
4 Technical data .............................................................................................. 21
4.1 Dimensions ................................................................................................................ 22
4.2 Cabinet Interface Board, Small Robot ....................................................................... 23
4.3 Dimensions of the smartPAD holder (optional) .......................................................... 24
4.4 Dimensions of handle brackets .................................................................................. 25
4.5 Plates and labels ........................................................................................................ 25
4.6 REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/2006 26
5 Safety ............................................................................................................ 27
5.1 General ...................................................................................................................... 27
5.1.1 Liability .................................................................................................................. 27
5.1.2 Intended use of the industrial robot ...................................................................... 27
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 28
5.1.4 Terms used ........................................................................................................... 28
5.2 Personnel ................................................................................................................... 30
5.3 Workspace, safety zone and danger zone ................................................................. 31
5.3.1 Determining stopping distances ............................................................................ 31
5.4 Triggers for stop reactions ......................................................................................... 32
5.5 Safety functions ......................................................................................................... 32
5.5.1 Overview of the safety functions ........................................................................... 32
5.5.2 Safety controller .................................................................................................... 33
Contents
Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Trademarks ................................................................................................................ 7
1.4 Terms used ................................................................................................................ 8
2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9
3 Product description ..................................................................................... 11
3.1 Description of the industrial robot .............................................................................. 11
3.2 Overview of the robot controller ................................................................................. 11
3.3 Control box ................................................................................................................. 12
3.3.1 Control PC ............................................................................................................ 12
3.3.2 Cabinet Control Unit, Small Robot ........................................................................ 13
3.3.3 Low-voltage power supply unit ............................................................................. 14
3.3.4 Batteries ................................................................................................................ 14
3.3.5 Mains filter ............................................................................................................ 14
3.4 Drive box (Drive Configuration (DC)) ......................................................................... 14
3.5 Description of interfaces ............................................................................................ 15
3.5.1 Control PC interfaces ............................................................................................ 16
3.5.1.1 Motherboard D3076-K PC interfaces ............................................................... 17
3.5.1.2 Motherboard D3236-K PC interfaces ............................................................... 18
3.5.1.3 Motherboard D3445-K PC interfaces ............................................................... 19
3.6 Cooling ....................................................................................................................... 20
4 Technical data .............................................................................................. 21
4.1 Dimensions ................................................................................................................ 22
4.2 Cabinet Interface Board, Small Robot ....................................................................... 23
4.3 Dimensions of the smartPAD holder (optional) .......................................................... 24
4.4 Dimensions of handle brackets .................................................................................. 25
4.5 Plates and labels ........................................................................................................ 25
4.6 REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/2006 26
5 Safety ............................................................................................................ 27
5.1 General ...................................................................................................................... 27
5.1.1 Liability .................................................................................................................. 27
5.1.2 Intended use of the industrial robot ...................................................................... 27
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 28
5.1.4 Terms used ........................................................................................................... 28
5.2 Personnel ................................................................................................................... 30
5.3 Workspace, safety zone and danger zone ................................................................. 31
5.3.1 Determining stopping distances ............................................................................ 31
5.4 Triggers for stop reactions ......................................................................................... 32
5.5 Safety functions ......................................................................................................... 32
5.5.1 Overview of the safety functions ........................................................................... 32
5.5.2 Safety controller .................................................................................................... 33
Contents
4 / 93 Issued: 20.04.2018 Version: Spez KR C4 compact V10
KR C4 compact
5.5.3 Selecting the operating mode ............................................................................... 33
5.5.4 “Operator safety” signal ........................................................................................ 34
5.5.5 EMERGENCY STOP device ................................................................................ 35
5.5.6 Logging off from the higher-level safety controller ................................................ 35
5.5.7 External EMERGENCY STOP device .................................................................. 36
5.5.8 Enabling device .................................................................................................... 36
5.5.9 External enabling device ...................................................................................... 37
5.5.10 External safe operational stop .............................................................................. 37
5.5.11 External safety stop 1 and external safety stop 2 ................................................. 37
5.5.12 Velocity monitoring in T1 ...................................................................................... 37
5.6 Additional protective equipment ................................................................................ 37
5.6.1 Jog mode .............................................................................................................. 37
5.6.2 Software limit switches ......................................................................................... 38
5.6.3 Mechanical end stops ........................................................................................... 38
5.6.4 Mechanical axis limitation (optional) ..................................................................... 38
5.6.5 Options for moving the manipulator without drive energy .................................... 38
5.6.6 Labeling on the industrial robot ............................................................................ 39
5.6.7 External safeguards ............................................................................................. 39
5.7 Overview of operating modes and safety functions ................................................... 40
5.8 Safety measures ........................................................................................................ 40
5.8.1 General safety measures ..................................................................................... 40
5.8.2 Transportation ...................................................................................................... 41
5.8.3 Start-up and recommissioning .............................................................................. 42
5.8.3.1 Checking machine data and safety configuration ............................................ 43
5.8.3.2 Start-up mode .................................................................................................. 45
5.8.4 Manual mode ........................................................................................................ 46
5.8.5 Simulation ............................................................................................................. 47
5.8.6 Automatic mode ................................................................................................... 47
5.8.7 Maintenance and repair ........................................................................................ 47
5.8.8 Decommissioning, storage and disposal .............................................................. 49
5.8.9 Safety measures for “single point of control” ........................................................ 49
5.9 Applied norms and regulations .................................................................................. 50
6 Planning ........................................................................................................ 53
6.1 Electromagnetic compatibility (EMC) ......................................................................... 53
6.2 Installation conditions ................................................................................................ 53
6.3 Connection conditions ............................................................................................... 54
6.4 Power supply connection ........................................................................................... 55
6.5 Safety interface X11 .................................................................................................. 55
6.5.1 X11 safety interface .............................................................................................. 55
6.5.2 Wiring example for E-STOP circuit and safeguard ............................................... 58
6.5.3 Wiring example for safe inputs and outputs ......................................................... 59
6.6 Safety functions via Ethernet safety interface ........................................................... 61
6.6.1 Schematic circuit diagram for enabling switches .................................................. 65
6.6.2 SafeOperation via Ethernet safety interface (optional) ......................................... 66
6.6.3 KUKA Line Interface X66 ..................................................................................... 69
6.7 Mastering test ............................................................................................................ 70
6.8 X65 EtherCAT interface ............................................................................................. 70
6.9 X69 KUKA Service Interface ..................................................................................... 71
KR C4 compact
5.5.3 Selecting the operating mode ............................................................................... 33
5.5.4 “Operator safety” signal ........................................................................................ 34
5.5.5 EMERGENCY STOP device ................................................................................ 35
5.5.6 Logging off from the higher-level safety controller ................................................ 35
5.5.7 External EMERGENCY STOP device .................................................................. 36
5.5.8 Enabling device .................................................................................................... 36
5.5.9 External enabling device ...................................................................................... 37
5.5.10 External safe operational stop .............................................................................. 37
5.5.11 External safety stop 1 and external safety stop 2 ................................................. 37
5.5.12 Velocity monitoring in T1 ...................................................................................... 37
5.6 Additional protective equipment ................................................................................ 37
5.6.1 Jog mode .............................................................................................................. 37
5.6.2 Software limit switches ......................................................................................... 38
5.6.3 Mechanical end stops ........................................................................................... 38
5.6.4 Mechanical axis limitation (optional) ..................................................................... 38
5.6.5 Options for moving the manipulator without drive energy .................................... 38
5.6.6 Labeling on the industrial robot ............................................................................ 39
5.6.7 External safeguards ............................................................................................. 39
5.7 Overview of operating modes and safety functions ................................................... 40
5.8 Safety measures ........................................................................................................ 40
5.8.1 General safety measures ..................................................................................... 40
5.8.2 Transportation ...................................................................................................... 41
5.8.3 Start-up and recommissioning .............................................................................. 42
5.8.3.1 Checking machine data and safety configuration ............................................ 43
5.8.3.2 Start-up mode .................................................................................................. 45
5.8.4 Manual mode ........................................................................................................ 46
5.8.5 Simulation ............................................................................................................. 47
5.8.6 Automatic mode ................................................................................................... 47
5.8.7 Maintenance and repair ........................................................................................ 47
5.8.8 Decommissioning, storage and disposal .............................................................. 49
5.8.9 Safety measures for “single point of control” ........................................................ 49
5.9 Applied norms and regulations .................................................................................. 50
6 Planning ........................................................................................................ 53
6.1 Electromagnetic compatibility (EMC) ......................................................................... 53
6.2 Installation conditions ................................................................................................ 53
6.3 Connection conditions ............................................................................................... 54
6.4 Power supply connection ........................................................................................... 55
6.5 Safety interface X11 .................................................................................................. 55
6.5.1 X11 safety interface .............................................................................................. 55
6.5.2 Wiring example for E-STOP circuit and safeguard ............................................... 58
6.5.3 Wiring example for safe inputs and outputs ......................................................... 59
6.6 Safety functions via Ethernet safety interface ........................................................... 61
6.6.1 Schematic circuit diagram for enabling switches .................................................. 65
6.6.2 SafeOperation via Ethernet safety interface (optional) ......................................... 66
6.6.3 KUKA Line Interface X66 ..................................................................................... 69
6.7 Mastering test ............................................................................................................ 70
6.8 X65 EtherCAT interface ............................................................................................. 70
6.9 X69 KUKA Service Interface ..................................................................................... 71
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Mainos
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