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Kuka KR C4 compact User Manual

Kuka KR C4 compact
93 pages
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Controller
KR C4 compact
Specification
KUKA Deutschland GmbH
Issued: 20.04.2018
Version: Spez KR C4 compact V10
KR C4 com-
pact

Table of Contents

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Kuka KR C4 compact Specifications

General IconGeneral
BrandKuka
ModelKR C4 compact
CategoryController
LanguageEnglish

Summary

1 Introduction

1.1 Industrial Robot Documentation

Details the various documents comprising the industrial robot documentation.

1.2 Representation of Warnings and Notes

Explains the meaning and usage of different warning and notice symbols.

1.3 Trademarks

Lists the trademarks registered by KUKA and other companies.

1.4 Terms Used

Provides definitions for technical terms and abbreviations used throughout the manual.

2 Purpose

2.1 Target Group

Defines the intended audience and their required technical knowledge for this manual.

2.2 Intended Use

Specifies the correct applications and prohibits any deviation from intended use.

3 Product Description

3.1 Description of the Industrial Robot

Outlines the main components that constitute an industrial robot system.

3.2 Overview of the Robot Controller

Provides a general overview of the robot controller and its managed systems.

3.3 Control Box

Describes the internal components housed within the robot controller's control box.

3.3.1 Control PC

Lists the components and key functions of the Control PC (KPC).

3.3.2 Cabinet Control Unit, Small Robot

Explains the function and role of the Cabinet Control Unit for small robots.

3.3.3 Low-Voltage Power Supply Unit

Describes the function of the low-voltage power supply unit.

3.3.4 Batteries

Explains the role of batteries in controlled shutdown procedures.

3.3.5 Mains Filter

Details the function of the mains filter for voltage suppression.

3.4 Drive Box (Drive Configuration (DC))

Outlines the components and functions of the Drive Configuration (DC) box.

3.5 Description of Interfaces

Details the standard and optional connection interfaces available on the controller.

3.5.1 Control PC Interfaces

Lists interfaces for the Control PC and motherboard variants.

3.5.1.1 Motherboard D3076-K PC Interfaces

Describes interfaces and slot assignments for the D3076-K motherboard.

3.5.1.2 Motherboard D3236-K PC Interfaces

Details interfaces and slot assignments for the D3236-K motherboard.

3.5.1.3 Motherboard D3445-K PC Interfaces

Outlines interfaces and slot assignments for the D3445-K motherboard.

3.6 Cooling

Explains the cooling circuits for the control and drive boxes.

4 Technical Data

4.1 Dimensions

Provides physical dimensions and technical specifications of the robot controller.

4.2 Cabinet Interface Board, Small Robot

Details the outputs and inputs of the Cabinet Interface Board.

4.3 Dimensions of the smartPAD Holder (Optional)

Shows dimensions and drilling locations for the smartPAD holder.

4.4 Dimensions of Handle Brackets

Illustrates dimensions for handle brackets.

4.5 Plates and Labels

Describes the plates and labels attached to the robot controller.

4.6 REACH Duty to Communicate Information

Information on substances of very high concern (SVHCs) in the product.

5 Safety

5.1 General

Covers liability, intended use, and general safety information.

5.1.1 Liability

Defines the manufacturer's and user's responsibilities regarding safety.

5.1.2 Intended Use of the Industrial Robot

Specifies the designated use and prohibits any misuse of the robot.

5.1.3 EC Declaration of Conformity and Incorporation

Explains conformity and incorporation declarations for machinery.

5.1.4 Terms Used

Defines safety-related terms and stop definitions according to standards.

5.2 Personnel

Defines roles (User, Personnel) and their safety obligations.

5.3 Workspace, Safety Zone and Danger Zone

Defines critical zones and safeguarding requirements for safe operation.

5.3.1 Determining Stopping Distances

Guides the process for determining necessary stopping distances for safety.

5.4 Triggers for Stop Reactions

Lists triggers for different stop reactions based on operating mode.

5.5 Safety Functions

Introduces the various safety functions available in the robot.

5.5.1 Overview of the Safety Functions

Lists and briefly describes standard safety functions.

5.5.2 Safety Controller

Describes the safety controller's role and tasks.

5.5.3 Selecting the Operating Mode

Explains the different operating modes (T1, T2, AUT, AUT EXT).

5.5.4 Operator Safety Signal

Details the function and importance of the operator safety signal.

5.5.5 EMERGENCY STOP Device

Covers the smartPAD E-STOP and external E-STOP requirements.

5.5.6 Logging Off from Higher-Level Controller

Explains consequences of disconnecting from a higher-level safety controller.

5.5.7 External EMERGENCY STOP Device

Stresses the need for external E-STOP devices for system safety.

5.5.8 Enabling Device

Describes the function and positions of the smartPAD enabling switches.

5.5.9 External Enabling Device

Explains when external enabling devices are necessary.

5.5.10 External Safe Operational Stop

Details the external safe operational stop function.

5.5.11 External Safety Stop 1 and External Safety Stop 2

Explains the functionality of external safety stop 1 and 2.

5.5.12 Velocity Monitoring in T1

Describes the velocity monitoring function in T1 mode.

5.6 Additional Protective Equipment

Introduces additional protective measures for robot operation.

5.6.1 Jog Mode

Explains jog mode operation in T1 and T2 modes.

5.6.2 Software Limit Switches

Explains the purpose and configuration of software limit switches.

5.6.3 Mechanical End Stops

Describes mechanical end stops for axis limitation and protection.

5.6.4 Mechanical Axis Limitation (Optional)

Details optional mechanical axis limitation systems for safety.

5.6.5 Options for Moving the Manipulator Without Drive Energy

Covers options for manual movement during emergencies or malfunctions.

5.6.6 Labeling on the Industrial Robot

Emphasizes the importance of not modifying or removing robot labels.

5.6.7 External Safeguards

Outlines requirements for physical and safety gate safeguards.

5.7 Overview of Operating Modes and Safety Functions

Table showing active safety functions per operating mode.

5.8 Safety Measures

General safety measures to prevent injury and damage.

5.8.1 General Safety Measures

Essential safety precautions for operation and maintenance.

5.8.2 Transportation

Specifies procedures for safely transporting manipulators and controllers.

5.8.3 Start-up and Recommissioning

Details checks and procedures before initial operation.

5.8.3.1 Checking Machine Data and Safety Configuration

Describes checks for machine data and safety configuration.

5.8.3.2 Start-up Mode

Explains the start-up mode and its associated risks.

5.8.4 Manual Mode

Covers setup work in manual mode (T1, T2).

5.8.5 Simulation

Notes on testing robot programs created in simulation.

5.8.6 Automatic Mode

Outlines safety measures for automatic mode operation.

5.8.7 Maintenance and Repair

Safety measures during maintenance and repair work.

5.8.8 Decommissioning, Storage and Disposal

Procedures for safe decommissioning, storage, and disposal.

5.8.9 Safety Measures for "Single Point of Control"

Safety measures for implementing single point of control (SPOC).

5.9 Applied Norms and Regulations

Lists relevant norms and regulations for machinery safety.

6 Planning

6.1 Electromagnetic Compatibility (EMC)

Guidelines for ensuring electromagnetic compatibility of the robot controller.

6.2 Installation Conditions

Specifies requirements for installing the robot controller in racks or standalone.

6.3 Connection Conditions

Details power supply and cable connection requirements.

6.4 Power Supply Connection

Describes how to connect the robot controller to the mains power.

6.5 Safety Interface X11

Explains the X11 safety interface and its wiring.

6.5.1 X11 Safety Interface

Details the pin allocation and function of the X11 interface.

6.5.2 Wiring Example for E-STOP Circuit and Safeguard

Illustrates wiring for E-STOP circuits and safety gates.

6.5.3 Wiring Example for Safe Inputs and Outputs

Shows connection schematics for safe inputs and outputs.

6.6 Safety Functions via Ethernet Safety Interface

Describes safety function exchange via Ethernet interface.

6.6.1 Schematic Circuit Diagram for Enabling Switches

Shows circuit diagrams for external enabling switches.

6.6.2 SafeOperation via Ethernet Safety Interface (Optional)

Explains the SafeOperation function via Ethernet safety interface.

6.6.3 KUKA Line Interface X66

Details the KUKA Line Interface X66 for external computers.

6.7 Mastering Test

Explains requirements and steps for the mastering test.

6.8 X65 EtherCAT Interface

Describes the EtherCAT interface X65 for connecting slaves.

6.9 X69 KUKA Service Interface

Details the KUKA Service Interface X69 for diagnostics and configuration.

6.10 PE Equipotential Bonding

Specifies required cables for PE equipotential bonding.

6.11 Performance Level

Covers safety performance levels and PFH values.

6.11.1 PFH Values of the Safety Functions

Lists PFH values for different safety functions and controller variants.

7 Transportation

7.1 Transporting the Robot Controller

Provides instructions for safely transporting the robot controller.

8 Start-up and Recommissioning

8.1 Installing the Robot Controller

Details requirements for installing the robot controller in racks or standalone.

8.2 Connecting the Connecting Cables

Explains how to connect system cables like motor and data cables.

8.3 Plugging in the KUKA smartPAD

Describes the procedure for connecting the smartPAD to the controller.

8.4 Connecting the Equipotential Bonding (PE)

Instructions for connecting PE equipotential bonding between components.

8.5 Connecting the Robot Controller to the Power Supply

Details how to connect the controller to the power supply.

8.6 Reversing the Battery Discharge Protection Measures

Explains how to connect the battery discharge protection measures.

8.7 Configuring and Connecting Connector X11

Outlines configuration and connection of the X11 safety interface connector.

8.8 Switching on the Robot Controller

Step-by-step guide for powering on the robot controller and its software.

9 KUKA Service

9.1 Requesting Support

Information required for processing a support request and troubleshooting.

9.2 KUKA Customer Support

Lists contact information for KUKA Customer Support by country.

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