Controller

KUKA Sunrise Cabinet

Operating Instructions

Issued: 06.05.2019
BA KUKA Sunrise Cabinet V10
KUKA Deutschland GmbH
KUKA Sunrise Cabinet

© Copyright 2019
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 soft-
ware 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 regu-
lar basis, however, 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 BA KUKA Sunrise Cabinet (PDF) en

PB4459

Book structure: BA KUKA Sunrise Cabinet V11.2

BS1603

Version: BA KUKA Sunrise Cabinet V10

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Contents

1 Introduction.............................................................................................. 7
1.1 Industrial robot documentation.............................................................................. 7
1.2 Representation of warnings and notes................................................................. 7
1.3 Trademarks............................................................................................................ 8
1.4 Terms used............................................................................................................ 8

2 Purpose..................................................................................................... 9
2.1 Target group.......................................................................................................... 9
2.2 Intended use.......................................................................................................... 9

3 Product description................................................................................. 11
3.1 Overview of the robot system............................................................................... 11
3.2 KUKA Sunrise Cabinet ........................................................................................ 11
3.3 Control PC............................................................................................................. 12
3.4 Cabinet Control Unit, Small Robot....................................................................... 13
3.5 Low-voltage power supply unit............................................................................. 13
3.6 Batteries................................................................................................................. 14
3.7 Mains filter............................................................................................................. 14
3.8 Description of interfaces........................................................................................ 14
3.8.1 Control PC interfaces............................................................................................ 15
3.8.1.1 Motherboard D3076-K PC interfaces.................................................................... 15
3.8.1.2 Motherboard D3236-K PC interfaces.................................................................... 16
3.8.1.3 Motherboard D3445-K PC interfaces.................................................................... 17
3.9 Cooling................................................................................................................... 18

4 Technical data.......................................................................................... 21
4.1 Cabinet Interface Board, Small Robot.................................................................. 23
4.2 External 24 V power supply.................................................................................. 24
4.3 Dimensions............................................................................................................ 24
4.4 Dimensions of the smartPAD holder (optional).................................................... 25
4.5 Dimensions of handle brackets............................................................................. 25
4.6 Plates and labels................................................................................................... 26

5 Safety......................................................................................................... 27
5.1 Legal framework.................................................................................................... 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
5.2 Safety functions..................................................................................................... 28
5.2.1 Terms used............................................................................................................ 29
5.2.2 Personnel............................................................................................................... 31
5.2.3 Workspace, safety zone and danger zone........................................................... 32
5.2.4 Safety-oriented functions....................................................................................... 33
5.2.4.1 EMERGENCY STOP device................................................................................. 34
5.2.4.2 Enabling device..................................................................................................... 34
5.2.4.3 “Operator safety” signal......................................................................................... 35
5.2.4.4 External EMERGENCY STOP device.................................................................. 35

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5.2.4.5 External safety stop 1 (path-maintaining) ........................................................... 35

5.2.4.6 External enabling device....................................................................................... 36
5.2.4.7 External safe operational stop.............................................................................. 36
5.2.5 Triggers for safety-oriented stop reactions........................................................... 36
5.2.6 Non-safety-oriented functions................................................................................ 37
5.2.6.1 Mode selection...................................................................................................... 37
5.2.6.2 Velocity monitoring in T1....................................................................................... 38
5.2.6.3 Software limit switches.......................................................................................... 39
5.3 Additional protective equipment............................................................................ 39
5.3.1 Jog mode............................................................................................................... 39
5.3.2 Labeling on the industrial robot............................................................................ 39
5.3.3 External safeguards............................................................................................... 39
5.4 Safety measures.................................................................................................... 40
5.4.1 General safety measures...................................................................................... 40
5.4.2 IT security.............................................................................................................. 42
5.4.3 Transportation........................................................................................................ 42
5.4.4 Start-up and recommissioning.............................................................................. 42
5.4.5 Manual mode......................................................................................................... 45
5.4.6 Automatic mode..................................................................................................... 46
5.4.7 Maintenance and repair........................................................................................ 46
5.4.8 Decommissioning, storage and disposal.............................................................. 47
5.4.9 Safety measures for “single point of control”....................................................... 47
5.5 Applied standards and directives.......................................................................... 48

6 Planning.................................................................................................... 49
6.1 Overview................................................................................................................ 49
6.2 Electromagnetic compatibility (EMC).................................................................... 49
6.3 Installation conditions............................................................................................ 50
6.4 Connection conditions........................................................................................... 51
6.5 Power supply connection...................................................................................... 52
6.6 Interface X11......................................................................................................... 52
6.6.1 Contact diagram, connector X11.......................................................................... 52
6.6.2 X11 safety interface............................................................................................... 53
6.6.3 Wiring example for E-STOP circuit and safeguard.............................................. 55
6.6.4 Wiring example for safe inputs and outputs........................................................ 55
6.7 KUKA Extension Bus X65..................................................................................... 57
6.8 KUKA Line Interface X66...................................................................................... 58
6.9 X69 KUKA Service Interface................................................................................. 59
6.10 Media flange interface X650................................................................................. 60
6.11 PE equipotential bonding...................................................................................... 60
6.12 Performance level.................................................................................................. 61
6.12.1 PFH values of the safety functions...................................................................... 61

7 Transportation.......................................................................................... 63
7.1 Transportation with trolley..................................................................................... 63
7.2 Transportation without trolley................................................................................ 63

8 Start-up and recommissioning............................................................... 65

8.1 Overview................................................................................................................ 65
8.2 Installing the robot controller................................................................................. 66

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8.3 Connecting the connecting cables........................................................................ 66

8.4 Plugging in the KUKA smartPAD.......................................................................... 67
8.5 Connecting the PE equipotential bonding............................................................ 67
8.6 Reversing the battery discharge protection measures......................................... 67
8.7 Configuring and connecting connector X11.......................................................... 68
8.8 Connecting the robot controller to the power supply........................................... 68
8.8.1 Connecting the robot controller to the power supply with a mains connector.... 68
8.8.2 Connecting the robot controller to the power supply without a mains connec-
tor........................................................................................................................... 69
8.9 Switching on the robot controller.......................................................................... 69

9 Operation.................................................................................................. 71
9.1 KUKA smartPAD teach pendant........................................................................... 71
9.1.1 Front view.............................................................................................................. 71
9.1.2 Rear view............................................................................................................... 73

10 Maintenance.............................................................................................. 75
10.1 Checking CCU_SR relay outputs......................................................................... 76
10.2 Cleaning the robot controller................................................................................. 76

11 Repair........................................................................................................ 79
11.1 Repair and procurement of spare parts............................................................... 79
11.2 Opening the housing cover................................................................................... 79
11.3 Exchanging the motherboard................................................................................ 80
11.4 Exchanging the motherboard battery.................................................................... 82
11.5 Exchanging the hard drive.................................................................................... 82
11.6 Exchanging the batteries....................................................................................... 83
11.7 Exchanging the fans.............................................................................................. 85
11.8 Installation of KUKA Sunrise.OS.......................................................................... 86

12 Troubleshooting....................................................................................... 87
12.1 LED display on Cabinet Control Unit, Small Robot............................................. 87
12.2 Fuses on the Cabinet Control Unit, Small Robot................................................ 91
12.3 Low-voltage power supply unit fuses................................................................... 93

13 Decommissioning, storage and disposal............................................. 95

13.1 Decommissioning................................................................................................... 95
13.2 Storage.................................................................................................................. 95
13.3 Disposal................................................................................................................. 96

14 KUKA Service........................................................................................... 97
14.1 Requesting support............................................................................................... 97
14.2 KUKA Customer Support...................................................................................... 97

Index 105

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Introduction
1 Introduction

1.1 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts in KUKA.Xpert
Each of these sets of instructions is a separate document.

1.2 Representation of warnings and notes

Safety

These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.

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

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

NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.

These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:
SAFETY INSTRUCTION
The following procedure must be followed exactly!

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.

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Introduction KUKA Sunrise Cabinet

1.3 Trademarks

• Windows is a trademark of Microsoft Corporation.

• EtherCAT® is a registered trademark and patented tech-

nology, licensed by Beckhoff Automation GmbH, Germany.

1.4 Terms used

Term Description
CCU_SR Cabinet Control Unit Small Robot
CIB_SR Cabinet Interface Board Small Robot
Dual NIC card Dual network card
EDS Electronic Data Storage (memory card)
EMC Electromagnetic compatibility
KCB KUKA Controller Bus
KEB KUKA Extension Bus
KEI KUKA Extension Interface
KLI KUKA Line Interface. Connection to higher-lev-
el control infrastructure (PLC, archiving)
KOI KUKA Option Interface
KONI KUKA Option Network Interface
KPC Control PC
KSB KUKA System Bus. Internal KUKA bus for in-
ternal networking of the controllers with each
other
KSI KUKA Service Interface
KSP_SR KUKA Servo Pack Small Robot
KSS KUKA System Software
Manipulator The robot arm and the associated electrical in-
stallations
PMB_SR Power Management Board Small Robot
SATA connections Data bus for exchanging data between the pro-
cessor and the hard drive
SSD Solid-State Drive (electronic storage medium)
USB Universal Serial Bus. Bus system for connect-
ing additional devices to a computer
EA External axis (linear unit, Posiflex)

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Purpose
2 Purpose

2.1 Target group

This documentation is aimed at users with the following knowledge and

skills:

• Advanced knowledge of electrical and electronic systems

• Advanced knowledge of the robot controller
• Advanced knowledge of the Windows operating system

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

take part in a course of training at KUKA College. Information about the
training program can be found at www.kuka.com or can be obtained di-
rectly from our subsidiaries.

2.2 Intended use

Use

The KUKA Sunrise Cabinet robot controller is intended solely for operating
KUKA axes in industrial applications. KUKA axes include, for example, in-
dustrial robots and mobile platforms.

Misuse

Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. KUKA Deutschland GmbH is not liable for any
damage resulting from such misuse. The risk lies entirely with the user.
Examples of such misuse include:
• Operating axes that are not KUKA axes
• Use for non-industrial applications for which specific product require-
ments/standards exist (e.g. medical applications)
• Use outside the permissible operating parameters
• Operation in potentially explosive environments
• Outdoor operation

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Product description
3 Product description

3.1 Overview of the robot system

A robot system (>>> Fig. 3-1) comprises all the assemblies of an industri-
al robot, including the manipulator (mechanical system and electrical in-
stallations), controller, connecting cables, end effector (tool) and other
equipment.
The industrial robot consists of the following components:
• Manipulator
• KUKA Sunrise Cabinet robot controller
• KUKA smartPAD control panel
• Connecting cables
• Software
• Options, accessories

Fig. 3-1: Overview of robot system

1 Connecting cable to the smartPAD

2 KUKA smartPAD control panel
3 Manipulator
4 Connecting cable to KUKA Sunrise Cabinet robot controller
5 KUKA Sunrise Cabinet robot controller

3.2 KUKA Sunrise Cabinet

Overview

The KUKA Sunrise Cabinet robot controller consists of the following com-
ponents:
• Control PC
• smartPAD control panel

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• Connection panel
The robot controller can be installed in a 19" rack.

Fig. 3-2: Control unit overview

1 Low-voltage power supply unit

2 Memory card (EDS)
3 Power Management Board, Small Robot (PMB_SR)
4 Cabinet Interface Board, Small Robot (CIB_SR)
5 Interfaces
6 Main switch, interfaces
7 Network connections cover
8 PC interfaces
9 Fans
10 Batteries
11 Options
12 Brake resistor

3.3 Control PC

Components

The control PC (KPC) includes the following components:

• Motherboard
• Processor
• Heat sink
• Memory modules
• Hard drive
• LAN Dual NIC network card (not present on all motherboard variants)

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Product description
3.4 Cabinet Control Unit, Small Robot

Description

The Cabinet Control Unit, Small Robot (CCU_SR) is the central power dis-
tributor and communication interface for all components of the robot con-
troller. The CCU_SR consists of the Cabinet Interface Board, Small Robot
(CIB_SR) and the Power Management Board, Small Robot (PMB_SR). All
data are transferred via this internal communication interface to the con-
troller 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.
The CCU_SR also incorporates sensing, control and switching functions.
The output signals are provided as electrically isolated outputs.

Functions

• Communication interface for the components of the robot controller

• Safe inputs and outputs
‒ Contactor activation
‒ 3 floating outputs
‒ 7 safe inputs
‒ Teach pendant plugged in
• Fan power supply monitoring
• Control box internal temperature
• The following components are connected to the KPC via the KUKA
Controller Bus:
‒ Power Drive System
• 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
• KUKA smartPAD
• Control PC quad-core processor
• Power Drive System
Power supply without battery backup
• Motor brakes
• Customer interface

3.5 Low-voltage power supply unit

Description

The low-voltage power supply unit provides power to the components of

the robot controller and supplies the manipulator drives with 48 V DC.
Two green LEDs indicate the operating state of the low-voltage power
supply unit.

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3.6 Batteries

In the event of a power failure, or if the power is switched off, the batter-
ies enable the robot controller to be shut down in a controlled manner.
The batteries are charged via the CCU_SR and the charge is checked
and indicated.

3.7 Mains filter

Description

The mains filter (interference suppressor filter) suppresses interference

voltages on the power cable.

3.8 Description of interfaces

Overview

The connection panel of the KUKA Sunrise Cabinet robot controller con-
sists as standard of connections for the following cables:
• Device connection cable
• Manipulator cable
• smartPAD cable
• Peripheral cables
The configuration of the connection panel varies according to the custom-
er-specific version and the options required.

Connection panel

Fig. 3-3: KUKA Sunrise Cabinet interfaces

Item Interface Item Interface

1 X11 interface 6 X21 Manipulator interface
2 X19 smartPAD interface 7 X66 KUKA Line Interface
3 X65 Extension interface 8 PE connections
4 X69 Service interface 9 K1 Power supply connec-
tion
5 X650 Interface for media 10 Control PC interfaces
flange

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Product description
All contactor, relay and valve coils that are connected to the robot con-
troller by the user must be equipped with suitable suppressor diodes.
RC elements and VCR resistors are not suitable.

3.8.1 Control PC interfaces

Motherboards

The following motherboard variants can be installed in the control PC:

• D3076-K
• D3236-K
• D3445-K

3.8.1.1 Motherboard D3076-K PC interfaces

Overview

Fig. 3-4: Motherboard D3076-K interfaces

1 Field bus cards, slots 1 to 4

2 Cover, field bus cards
3 2 USB 2.0 ports
4 DVI-I
5 4 USB 2.0 ports
6 LAN Onboard – KUKA Option Network Interface

KUKA Deutschland GmbH has assembled, tested and supplied the

motherboard with an optimum configuration. No liability will be accepted
for modifications to the configuration that have not been carried out by
KUKA Deutschland GmbH.

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Slot assignment

Fig. 3-5: Motherboard slot assignment

The PC slots can be fitted with the following plug-in cards:

Slot Type Plug-in card
1 PCI Field bus
2 PCI Field bus
3 PCI Field bus
4 PCI Field bus
5 PCIe not available
6 PCIe not available
7 PCIe LAN Dual NIC network card

3.8.1.2 Motherboard D3236-K PC interfaces

Overview

Fig. 3-6: Motherboard D3236-K interfaces

1 Field bus cards, slots 1 to 2

2 Cover
3 2 USB 3.0 ports
4 DVI-I
5 4 USB 2.0 ports
6 LAN Onboard – KUKA Option Network Interface

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Product description
KUKA Deutschland GmbH has assembled, tested and supplied the
motherboard with an optimum configuration. No liability will be accepted
for modifications to the configuration that have not been carried out by
KUKA Deutschland GmbH.

Slot assignment

Fig. 3-7: Motherboard slot assignment

The PC slots can be fitted with the following plug-in cards:

Slot Type Plug-in card
1 PCI Field bus
2 PCI Field bus
3 - Not available
4 - Not available
5 - Not available
6 - Not available
7 - Not available

3.8.1.3 Motherboard D3445-K PC interfaces

Overview

Fig. 3-8: Motherboard D3445-K interfaces

1 Field bus cards, slots 1 to 2

2 Cover
3 2 USB 2.0 ports
4 DVI-D

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5 Display port
6 4 USB 2.0 ports
7 LAN Onboard – KUKA Line Interface

VGA support is possible via DP on VGA adapter. The user interface of

the controller can only be displayed on an external monitor if no active
operator control device (smartPAD, VRP) is connected to the controller.

KUKA Deutschland GmbH has assembled, tested and supplied the

motherboard with an optimum configuration. No liability will be accepted
for modifications to the configuration that have not been carried out by
KUKA Deutschland GmbH.

Slot assignment

Fig. 3-9: Slot assignment, motherboard D3445-K

Slot Type Plug-in card

1 PCI Field bus
2 PCI Field bus
3 - not available
4 - not available
5 PCIe not available
6 - not available
7 - not available

3.9 Cooling

Description

The components of the control and power electronics are cooled with am-
bient air by 2 fans.
NOTICE
Upstream installation of filter mats at the ventilation slits causes an in-
crease in temperature, leading to a reduction in the service life of the
installed devices!

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Product description
Cooling circuit, control box

Fig. 3-10: Cooling circuit, control box

1 Air inlet 3 Air outlet

2 Fan

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Technical data
4 Technical data
Basic data

Cabinet type KUKA Sunrise Cabinet (19" hous-

ing)
Color RAL 7016
Weight 23 kg
Protection rating IP 20
Sound level according to average: 54 dB (A)
DIN 45635-1

Power supply connection

The robot controller may only be connected to grounded-neutral power

supply systems.
Rated supply voltage 110 V/230 V AC, single-phase
Permissible tolerance of rated sup- Rated supply voltage ±10%
ply voltage
Mains frequency 50 Hz ± 1 Hz or 60 Hz ± 1 Hz
Rated power input 1 kVA, see rating plate
Thermal power dissipation 370 W
Mains-side fusing 2x 15 A slow-blowing (1x phase;
1x neutral conductor (optional))
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 conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Temperature change 1.1 K/min
Ambient temperature
During operation 5 °C to 45 °C (278 K to 318 K)
During storage/transportation -25 °C to 40 °C (248 K to 313 K)
During operation with cooling unit -
During storage/transportation with- -25 °C to 70 °C (248 K to 343 K)
out battery
Altitude
Without derating max. 1000 m above mean sea lev-
el

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With derating max. 3000 m above mean sea lev-

el (derating 5%/1000 m)

NOTICE
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.
If the storage temperature is between +30 °C and +40 °C, the batteries
must be recharged every 3 months.

Vibration resistance

r.m.s. acceleration (sustained oscillation)

During operation 0.1 g
During transportation 0.37 g
Frequency range (sustained oscillation)
During operation 4...120 Hz
During transportation 4...120 Hz
Acceleration (shock in X/Y/Z direction)
During operation 2.5 g
During transportation 10 g
Waveform/duration (shock in X/Y/Z direction)
During operation Half-sine/11 ms
During transportation Half-sine/11 ms
If more severe mechanical stress is expected, the controller must be in-
stalled on anti-vibration components.

Control unit

Supply voltage DC 27.1 V ± 0.1 V

Main processor Quad-core

DIMM memory modules See shipping version (min. 2 GB)
Hard drive SSD

KUKA smartPAD

Supply voltage 20 … 27.1 V DC

Dimensions (WxHxD) approx. 33x26x8 cm
Display Touch-sensitive color display
600x800 pixels
Display size 8.4"
Interfaces USB
Weight 1.1 kg

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Technical data
Cable lengths

For cable designations, standard lengths and optional lengths, please

refer to the operating instructions or assembly instructions of the manipu-
lator.
When using smartPAD cable extensions, only two extensions may be
used. An overall cable length of 50 m must not be exceeded.

4.1 Cabinet Interface Board, Small Robot

The power contacts must only be fed from a safely isolated PELV
power supply unit. (>>> 4.2 "External 24 V power supply" Page 24)

CIB_SR outputs

Operating voltage, power ≤ 30 V

contacts
Current via power contact min. 10 mA
< 750 mA
Cable lengths (connection < 50 m cable lengths
of actuators)
< 100 m wire length (outgoing and incom-
ing lines)
Cable cross-section (con- ≥ 1 mm2
nection of actuators)
Switching cycles CIB_SR Service life: 20 years
< 100,000 (corresponds to 13 switching
cycles per day)
The module must be exchanged when the number of switching cycles is
exceeded.

CIB_SR inputs

Switching level of the in- The state for the inputs is not defined for
puts the voltage range from 5 V to 11 V (tran-
sition 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 > 10 mA
supply voltage
Load current with 18 V > 6.5 mA
supply voltage
Max. load current < 15 mA
Cable length, terminal - < 50 m, or < 100 m wire length (outgoing
sensor and incoming lines)
Cable cross-section, test > 0.5 mm2
output - input connection
Capacitive load for the test < 200 nF
outputs per channel

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Resistive load for the test < 33 Ω

outputs per channel

Test outputs A and B are sustained short-circuit proof.

The specified currents flow via the contact element connected to the in-
put. This must be rated for the maximum current of 15 mA.

4.2 External 24 V power supply

PELV external power supply

External voltage PELV power supply unit acc. to

EN 60950 with rated voltage 27 V
(18 V ... 30 V), safely isolated
Continuous current > 8 A
Cable cross-section of power sup- ≥ 1 mm2
ply cable
Cable length of power supply cable < 50 m, or < 100 m wire length
(outgoing 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.

4.3 Dimensions

The dimensions of the robot controller are indicated in the diagram

(>>> Fig. 4-1).

Fig. 4-1: Dimensions

1 Top view 3 Side view

2 Front view

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Technical data
4.4 Dimensions of the smartPAD holder (optional)

The diagram shows the dimensions and drilling locations for mounting on
the safety fence.

Fig. 4-2: Dimensions and drilling locations for smartPAD holder

4.5 Dimensions of handle brackets

Fig. 4-3: Dimensions of handle brackets

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4.6 Plates and labels

Designations

The following plates and labels are attached to the robot controller. They
must not be removed or rendered illegible. Illegible plates and labels must
be replaced.

Fig. 4-4: Plates and labels

Item Description
1

Robot controller rating plate

2

Electric shock hazard

The operating instructions and safety regulations must be read
and understood before work is carried out on the robot control-
ler.
3

Remove mains connector

Unplug mains connector before opening the housing.

The plates may vary slightly from the examples illustrated above de-
pending on the specific cabinet type or as a result of updates.

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5 Safety

5.1 Legal framework

5.1.1 Liability

The device described in this document is either an industrial robot or a

component thereof.
Components of the industrial robot:

• Manipulator
• Robot controller
• Hand-held control panel
• Connecting cables
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial 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 ac-
cordance with its designated use and only by safety-conscious persons
who are fully aware of the risks involved in its operation. Use of the indus-
trial robot is subject to compliance with this document and with the decla-
ration of incorporation supplied together with the industrial robot. Any func-
tional disorders affecting safety must be rectified immediately.

Safety information

Information about safety may not be construed against KUKA Deutschland

GmbH. Even if all safety instructions are followed, this is not a guarantee
that the industrial robot will not cause personal injuries or material dam-
age.
No modifications may be carried out to the industrial robot without the au-
thorization of KUKA Deutschland GmbH. Unauthorized modifications will
result in the loss of warranty and liability claims.
Additional components (tools, software, etc.), not supplied by KUKA
Deutschland GmbH, may be integrated into the industrial robot. The user
is liable for any damage these components may cause to the industrial ro-
bot or to other material property.
In addition to the Safety chapter, this document contains further safety in-
structions. 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
“Purpose” 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. It will result in the loss of warranty and liability
claims.
Operation of the industrial robot in accordance with its intended use also
requires compliance with the operating and assembly instructions for the
individual components, with particular reference to the maintenance speci-
fications.

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The user is responsible for carrying out a risk assessment. This indicates
Safety

the additional safety equipment that is required, the installation of which is

also the responsibility of the user.

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 specified operating parameters
• Operation without the required safety equipment

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 op-
eration 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
complete system.
or: All safety functions and safeguards required for operation in the
complete 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 conformity

The system integrator must issue an EC declaration of conformity for the

complete system in accordance with the Machinery Directive. The EC dec-
laration 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 incorporation

The partly completed machinery is supplied with a declaration of incorpo-

ration in accordance with Annex II B of the Machinery Directive
2006/42/EC. The assembly instructions and a list of essential require-
ments complied with in accordance with Annex I are integral parts of this
declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly
completed 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.

5.2 Safety functions

Safety functions are distinguished according to the safety requirements

that they fulfill:

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• Safety-oriented functions for the protection of personnel
The safety-oriented functions of the industrial robot meet the following
safety requirements:
‒ Category 3 and Performance Level d in accordance with EN ISO
13849-1
‒ SIL 2 according to EN 62061
The requirements are only met on the following condition, however:
‒ All safety-relevant mechanical and electromechanical components
of the industrial robot are tested for correct functioning during start-
up and at least once every 12 months, unless otherwise deter-
mined in accordance with a workplace risk assessment. These in-
clude:
‒ Local EMERGENCY STOP device on the teach pendant
‒ Enabling device on the teach pendant
‒ Enabling device on the hand guiding device (if present)
‒ External enabling devices (if present)
‒ Keyswitch on the smartPAD (if used as teach pendant)
‒ Safety-oriented outputs of the discrete safety interface

Details about safety parameters (e.g. PFH, SIL, Performance Level)

are also available as a SISTEMA library. The library can be down-
loaded from the KUKA website.

• Non-safety-oriented functions for the protection of machines

The non-safety-oriented functions of the industrial robot do not meet
specific safety requirements:

DANGER
In the absence of the required operational safety functions and safe-
guards, the industrial robot can cause personal injury or material dam-
age. If the required safety functions or safeguards are dismantled or de-
activated, 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 integrated
into this safety system of the overall system.

5.2.1 Terms used

Term Description
Axis range Range within which the axis may move The axis range must be de-
fined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance
The stopping distance is part of the danger zone.
Workspace The manipulator is allowed to move within its workspace. The work-
space is derived from the individual axis ranges.
Automatic (AUT) Operating mode for program execution. The manipulator moves at the
programmed velocity.
Operator The user of the industrial robot can be the management, employer or
(User) delegated person responsible for use of the industrial robot.

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Term Description
Danger zone The danger zone consists of the workspace and the stopping distan-
ces.
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 in a
robot controller or elsewhere or not, as safety-relevant components
are also subject to aging during storage.
CRR Controlled Robot Retraction
CRR is an operating mode which can be selected when the industrial
robot is stopped by the safety controller for one of the following rea-
sons:

• Industrial robot violates an axis-specific or Cartesian monitoring

space.
• Orientation of a safety-oriented tool is outside the monitored
range.
• Industrial robot violates a force or axis torque monitoring function.
• A position sensor is not mastered or referenced.
• An axis torque sensor is not referenced.
After changing to CRR mode, the industrial robot may once again be
moved.
KUKA smartPAD see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The manipulator is not allowed to move within the safety zone. The
safety zone is the area outside the danger zone.
Safety stop The safety stop is triggered by the safety controller, interrupts the
work procedure and causes all robot motions to come to a standstill.
The program data are retained in the case of a safety stop and the
program can be resumed from the point of interruption.
The safety stop can be executed as a Stop category 0, Stop catego-
ry 1 or Stop category 1 (path-maintaining).
Note: In this document, a safety stop of Stop category 0 is referred
to as safety stop 0, a safety stop of Stop category 1 as safety stop 1
and a safety stop of Stop category 1 (path-maintaining) as safety
stop 1 (path-maintaining).
smartPAD The smartPAD is the hand-held control panel for the robot cell (sta-
tion). It has all the operator control and display functions required for
operation of the station.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
Stop category 1 The manipulator is braked and does not stay on the programmed
path. The manipulator is brought to a standstill with the drives. As
soon as an axis is at a standstill, the drive is switched off and the
brake is applied.
The internal electronic drive system of the robot performs safety-orien-
ted monitoring of the braking process. Stop category 0 is executed in
the event of a fault.
Note: Stop category 1 is currently only supported by the LBR iiwa.
For other manipulators, Stop category 0 is executed.

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Term Description
Stop category 1 The manipulator is braked and stays on the programmed path. At
(path-maintaining) standstill, the drives are deactivated and the brakes are applied.
If Stop category 1 (path-maintaining) is triggered by the safety control-
ler, the safety controller monitors the braking process. The brakes are
applied and the drives are switched off after 1 s at the latest. Stop
category 1 is executed in the event of a fault.
System integrator System integrators are people who safely integrate the industrial robot
(plant integrator) into a complete system and commission it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
Note: With manual guidance in T1, the velocity is not reduced, but
rather limited through a safety-oriented velocity monitoring in accord-
ance with the safety configuration.
Note: The maximum velocity of 250 mm/s does not apply to a mobile
platform.
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

5.2.2 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 under-
stood 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 exist. Instruction must be carried out regularly. Instruction is also re-
quired 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 repair

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

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System integrator

The industrial robot is safely integrated into a complete system by the sys-
tem 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

Operators

The operator must meet the following preconditions:

• The operator must be trained for the work to be carried out.
• Work on the system must only be carried out by qualified personnel.
These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are
able to assess the work to be carried out and detect any potential
hazards.

Work on the electrical and mechanical equipment of the manipulator

may only be carried out by KUKA Deutschland GmbH.

5.2.3 Workspace, safety zone and danger zone

Working zones are to be restricted to the necessary minimum size in or-

der to prevent danger to persons or the risk of material damage. Safely
monitored axis limits that limit the motion range of an axis and are re-
quired for personnel protection are configurable.
Further information about configuring safely monitored axis limits is con-
tained in the “Safety configuration” chapter of the operating and pro-
gramming instructions of the system software for system integrators.

The danger zone consists of the workspace and the stopping distances of
the manipulator. In the event of a stop, the manipulator is braked and
comes to a stop within the danger zone. The safety zone is the area out-
side the danger zone.
The danger zone must be protected by means of physical safeguards,
e.g. by light barriers, light curtains or safety fences. If there are no physi-
cal safeguards present, the requirements for collaborative operation in ac-
cordance with EN ISO 10218 must be met. There must be no shearing or
crushing hazards at the loading and transfer areas.

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Safety
Fig. 5-1: Example: axis range A1

1 Workspace 3 Stopping distance

2 Manipulator 4 Safety zone

5.2.4 Safety-oriented functions

The following safety-oriented functions are present and permanently de-

fined in the industrial robot:
• EMERGENCY STOP device
• Enabling device
The following safety-oriented functions are preconfigured and can be inte-
grated into the system via the safety interface of the robot controller:
• Operator safety (= connection for the monitoring of physical safe-
guards)
• External EMERGENCY STOP device
• External safety stop 1 (path-maintaining)
Other safety-oriented functions can also be configured, e.g.:
• External enabling device
• External safe operational stop
• Axis-specific workspace monitoring
• Cartesian workspace monitoring
• Cartesian protected space monitoring
• Velocity monitoring
• Standstill monitoring
• Axis torque monitoring
• Collision detection

Further information about configuring the safety functions is contained in

the “Safety configuration” chapter of the operating and programming in-
structions of the system software for system integrators.

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The preconfigured safety functions are described in the following sections

Safety

on safety.

5.2.4.1 EMERGENCY STOP device

As standard, the EMERGENCY STOP device of the industrial robot is the

EMERGENCY STOP device on the smartPAD teach pendant. The EMER-
GENCY STOP device must be pressed in the event of a hazardous situa-
tion or emergency.
Reaction of the industrial robot if the EMERGENCY STOP device is
pressed:
• The manipulator stops with a safety stop 1 (path-maintaining).
Before operation can be resumed, the EMERGENCY STOP device must
be turned to release it.
From KUKA Sunrise.OS 2.4 onwards, the inputs for the local EMER-
GENCY STOP can be configured, i.e. a different EMERGENCY STOP
device can be connected and used for the local EMERGENCY STOP.

WARNING
Tools and other equipment connected to the robot must be integrated in-
to the EMERGENCY STOP circuit on the system side if they could con-
stitute a potential hazard.
Failure to observe this precaution may result in death, severe injuries or
considerable damage to property.

If a holder is used for the teach pendant and conceals the EMERGENCY
STOP device on the teach pendant, an external EMERGENCY STOP de-
vice must be installed that is accessible at all times.
(>>> 5.2.4.4 "External EMERGENCY STOP device" Page 35)

5.2.4.2 Enabling device

As standard, the enabling device of the industrial robot is the enabling de-
vice on the smartPAD teach pendant.
There are 3 enabling switches installed on the smartPAD. The enabling
switches have 3 positions:
• Not pressed
• Center position
• Fully pressed (panic position)
In the test modes and in CRR, 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 1 (path-maintain-
ing).
• Fully pressing the enabling switch triggers a safety stop 1 (path-main-
taining).

From KUKA Sunrise.OS 2.4 onwards, the inputs of the enabling device
for the teach pendant can be configured, i.e. a different teach pendant
with enabling device can be connected and used.

If an enabling switch malfunctions (e.g. jams in the center position), the

industrial robot can be stopped using one of the following methods:

• Press another enabling switch down fully.

• Actuate the EMERGENCY STOP device.

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Safety
• Release the Start key.

WARNING
The enabling switches must not be held down by adhesive tape or other
means or tampered with in any other way.
Death, injuries or damage to property may result.

5.2.4.3 “Operator safety” signal

The “operator safety” signal is used for monitoring physical safeguards,

e.g. safety gates. In the default configuration, T2 and automatic operation
are not possible without this signal. Alternatively, the requirements for col-
laborative operation in accordance with EN ISO 10218 must be met.
Reaction of the industrial robot in the event of a loss of signal during T2
or automatic operation (default configuration):
• The manipulator stops with a safety stop 1 (path-maintaining).
By default, operator safety is not active in the modes T1 (Manual Re-
duced Velocity) and CRR, i.e. the signal is not evaluated.
WARNING
Following a loss of signal, automatic operation must not be resumed
merely by closing the safeguard; the signal for operator safety must first
be set by an additional device, e.g. by an acknowledge button. It is the
responsibility of the system integrator to ensure this. This is to prevent
automatic operation from being resumed inadvertently while there are
still persons in the danger zone, e.g. due to the safety gate closing ac-
cidentally.
• This additional device must be designed in such a way that an ac-
tual check of the danger zone can be carried out first. Devices that
do not allow this (e.g. because they are automatically triggered by
closure of the safeguard) are not permitted.
• Failure to observe this may result in death to persons, severe inju-
ries or considerable damage to property.

5.2.4.4 External EMERGENCY STOP device

Every operator station that can initiate a robot motion or other potentially
hazardous situation must be equipped with an EMERGENCY STOP de-
vice. The system integrator is responsible for ensuring this.
Reaction of the industrial robot if the external EMERGENCY STOP device
is pressed (default configuration):
• The manipulator stops with a safety stop 1 (path-maintaining).
External EMERGENCY STOP devices are connected via the safety inter-
face of the robot controller. External EMERGENCY STOP devices are not
included in the scope of supply of the industrial robot.

5.2.4.5 External safety stop 1 (path-maintaining)

The external safety stop 1 (path-maintaining) can be triggered via an input

on the safety interface (default configuration). 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 acknowledgement is required.

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5.2.4.6 External enabling device

Safety

External enabling devices are required if it is necessary for more than one
person to be in the danger zone of the industrial robot.
Multiple external enabling devices can be connected via the safety inter-
face of the robot controller. External enabling devices are not included in
the scope of supply of the industrial robot.
An external enabling device can be used for manual guidance of the ro-
bot. When enabling is active, the robot may only be moved at reduced ve-
locity.
For manual guidance, safety-oriented velocity monitoring with a maximum
permissible velocity of 250 mm/s is preconfigured. The maximum permissi-
ble velocity can be adapted.
The value for the maximum permissible velocity must be determined as
part of a risk assessment.

5.2.4.7 External 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 stationary.
The safe operational stop can be triggered via an input on the safety in-
terface. 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
acknowledgement is required.

5.2.5 Triggers for safety-oriented stop reactions

Stop reactions are triggered in response to operator actions or as a reac-

tion to monitoring functions and errors. The following tables show the dif-
ferent stop reactions according to the operating mode that has been set.

Overview

In KUKA Sunrise a distinction is made between the following triggers:

• Permanently defined triggers

Permanently defined triggers for stop reactions and the associated
stop category are preset by the system and cannot be changed. How-
ever, it is possible for the implemented stop reaction to be stepped up
in the user-specific safety configuration.
• User-specific triggers
In addition to the permanently defined triggers, the user can also con-
figure other triggers for stop reactions including the associated stop
category.

Further information about configuring the safety functions is contained in

the “Safety configuration” chapter of the operating and programming in-
structions of the system software for system integrators.

Permanently defined triggers

The following triggers for stop reactions are permanently defined:

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Safety
Trigger T1, T2, CRR AUT
Operating mode changed Safety stop 1 (path-maintaining)
during operation
Enabling switch released Safety stop 1 (path- -
maintaining)
Enabling switch pressed Safety stop 1 (path- -
fully down (panic position) maintaining)
Local E-STOP pressed Safety stop 1 (path-maintaining)
Error in safety controller Safety stop 1

User-specific triggers

When creating a new Sunrise project, the system automatically generates

a project-specific safety configuration. This contains the following user-
specific stop reaction triggers preconfigured by KUKA (in addition to the
permanently defined triggers):
Trigger T1, CRR T2, AUT
Safety gate opened (op- - Safety stop 1 (path-
erator safety) maintaining)
External E-STOP pressed Safety stop 1 (path-maintaining)
External safety stop Safety stop 1 (path-maintaining)

This default safety configuration is valid for the system software without
additionally installed option packages or catalog elements. If additional
option packages or catalog elements have been installed, the default
safety configuration may be modified.

Triggers for manual guidance

If an enabling device is configured for manual guidance, the following ad-

ditional triggers for stop reactions are permanently defined:
Trigger T1, CRR T2, AUT
Manual guidance ena- Safety stop 1 (path- -
bling switch released maintaining)
Manual guidance ena- Safety stop 1 (path- -
bling switch pressed fully maintaining)
down (panic position)
Maximum permissible ve- Safety stop 1 (path-maintaining)
locity exceeded while
manual guidance ena-
bling signal is set
A maximum permissible velocity of 250 mm/s is preconfigured for manual
guidance. The maximum permissible velocity can be adapted.
The value for the maximum permissible velocity must be determined as
part of a risk assessment.

5.2.6 Non-safety-oriented functions

5.2.6.1 Mode selection

The industrial robot can be operated in the following modes:

• Manual Reduced Velocity (T1)

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• Manual High Velocity (T2)

• Automatic (AUT)
• Controlled robot retraction (CRR)

Operating
Use Velocities
mode
T1 Programming, teaching and testing of • Program verification:
programs.
Reduced programmed velocity,
maximum 250 mm/s
• Jog mode:
Jog velocity, maximum 250 mm/s
• Manual guidance:
No limitation of the velocity, but
safety-oriented velocity monitoring
in accordance with the safety con-
figuration
Note: The maximum velocity of
250 mm/s does not apply to a mobile
platform.
T2 Testing of programs • Program verification:
Programmed velocity
• Jog mode: Not possible
AUT Automatic execution of programs • Program operation:
For industrial robots with and without Programmed velocity
higher-level controllers • Jog mode: Not possible
CRR CRR is an operating mode which can • Program verification:
be selected when the industrial robot
Reduced programmed velocity,
is stopped by the safety controller for
maximum 250 mm/s
one of the following reasons:
• Jog mode:
• Industrial robot violates an axis- Jog velocity, maximum 250 mm/s
specific or Cartesian monitoring
• Manual guidance:
space.
No limitation of the velocity, but
• Orientation of a safety-oriented tool
safety-oriented velocity monitoring
is outside the monitored range.
in accordance with the safety con-
• Industrial robot violates a force or figuration
axis torque monitoring function.
• A position sensor is not mastered
or referenced.
• An axis torque sensor is not refer-
enced.
After changing to CRR mode, the in-
dustrial robot may once again be
moved.

5.2.6.2 Velocity monitoring in T1

The reduced velocity in T1 does not constitute a safety-rated reduced

speed in the standard safety configuration, i.e. the maximum permissible
velocity of 250 mm/s in T1 is not subjected to safety-oriented monitoring.
If the application requires safety-oriented velocity monitoring in T1, this
can be added in the safety configuration. The safety option KUKA Sun-

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rise.SafeOperation provides the monitoring function Cartesian velocity

Safety
monitoring for this purpose.
Further information about configuring safety-oriented velocity monitoring
for T1 is contained in the “Safety configuration” chapter of the operating
and programming instructions of the system software for system integra-
tors.

5.2.6.3 Software limit switches

The axis ranges of all manipulator axes are limited by means of non-safe-
ty-oriented software limit switches. These software limit switches only
serve as machine protection and are preset in such a way that the manip-
ulator is stopped under servo control if the axis limit is exceeded, thereby
preventing damage to the mechanical equipment.

5.3 Additional protective equipment

5.3.1 Jog mode

In the operating modes T1 (Manual Reduced Velocity), T2 (Manual High

Velocity) and CRR, 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 on the smartPAD triggers a safety
stop 1 (path-maintaining).
• Pressing fully down on the enabling switch on the smartPAD triggers a
safety stop 1 (path-maintaining).
• Releasing the Start key triggers a stop of Stop category 1 (path-main-
taining).

5.3.2 Labeling on the industrial robot

All plates, labels, symbols and marks constitute safety-relevant parts of

the industrial 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 in-

structions or assembly instructions of the components of the industrial
robot.

5.3.3 External safeguards

The access of persons to the danger zone of the industrial robot must be
prevented by means of safeguards. Alternatively, the requirements for col-
laborative operation in accordance with EN ISO 10218 must be met. It is
the responsibility of the system integrator to ensure this.

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Physical safeguards must meet the following requirements:

Safety

• 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 out-
side the enclosure.
• They do not, themselves, represent a hazard or potential hazard.
• The prescribed minimum clearance from the danger zone is main-
tained.
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 configured
operator safety inputs of the robot controller.
• Switching devices, switches and the type of switching conform to the
requirements of Performance Level d and category 3 according to EN
ISO 13849-1.
• Depending on the risk situation: the safety gate is additionally safe-
guarded by means of a locking mechanism that only allows the gate
to be opened if the manipulator is safely at a standstill.
• The device for setting the signal for operator safety, e.g. 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 reg-

ulations. These also include EN ISO 14120.

Other safety equipment

Other safety equipment must be integrated into the system in accordance

with the corresponding standards and regulations.

5.4 Safety measures

5.4.1 General safety measures

The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons. Op-
erator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial ro-
bot even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake de-
fect) can cause the manipulator to sag. If work is to be carried out on a
switched-off industrial robot, the manipulator must first be moved into a
position in which it is unable to move on its own, whether the payload is
mounted or not. If this is not possible, the manipulator must be secured
by appropriate means.
DANGER
In the absence of operational safety functions and safeguards, the in-
dustrial robot can cause personal injury or material damage. If safety
functions or safeguards are dismantled or deactivated, the industrial ro-
bot may not be operated.

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WARNING
Standing underneath the robot arm can cause death or serious injuries.
Especially if the industrial robot is moving objects that can become de-
tached (e.g. from a gripper). For this reason, standing underneath the
robot arm is prohibited!

HRC

In the case of collaborative operation (HRC), the system must be equip-

ped with a visual display indicating when the robot is in collaborative op-
eration.

smartPAD

The user must ensure that the industrial robot is only operated with the
smartPAD by authorized persons.
If more than one smartPAD is used in the overall system, it must be en-
sured that each smartPAD is unambiguously assigned to the correspond-
ing industrial robot. It must be ensured that 2 smartPADs are not inter-
changed.
The smartPAD can be configured as unpluggable.
WARNING
If the smartPAD is disconnected, the system can no longer be switched
off by means of the EMERGENCY STOP device on the smartPAD. If
the smartPAD is configured as unpluggable, at least one external
EMERGENCY STOP device must be installed that is accessible at all
times.
Failure to observe this can lead to death, injury or property damage.

WARNING
The operator must ensure that disconnected smartPADs are
immediately removed from the system and stored out of sight and reach
of personnel working on the industrial robot. This prevents operational
and non-operational EMERGENCY STOP devices from becoming inter-
changed.
Failure to observe this can lead to death, injury or property damage.

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
Velocity 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
components of the industrial robot and includes modifications to the soft-
ware and configuration settings.
The robot may not be connected and disconnected when the robot con-
troller is running.

Faults

The following tasks must be carried out in the case of faults in the indus-
trial robot:

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• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
• Eliminate the fault and carry out a function test.

5.4.2 IT security

The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons.
In particular, security-conscious use includes that it be operated in an IT
environment which meets the current security-relevant standards and for
which there is an overall concept for IT security.
IT security entails not only technical aspects but, at a minimum, also
those of organization, personnel and infrastructure.
KUKA urgently recommends that operators implement an information se-
curity management system for their products which designs, coordinates
and monitors the tasks related to information security.

Sources for information about IT security for companies include:

• Independent consulting firms
• National cyber security authorities
National authorities often make their recommendations available on the In-
ternet. In addition to their official language, some national authorities pro-
vide their information in English.

5.4.3 Transportation

Manipulator

The prescribed transport position of the manipulator must be observed.

Transportation must be carried out in accordance with the operating in-
structions 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 in-
structions or assembly instructions of the robot controller.
Avoid vibrations and impacts during transportation in order to prevent
damage to the robot controller.

5.4.4 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be
carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
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.

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Prior to start-up, the passwords for the user groups must be modified by
the administrator, transferred to the robot controller in an installation pro-
cedure and activated. The passwords must only be communicated to
authorized personnel.

DANGER
The robot controller is preconfigured for the specific industrial robot. If
cables are interchanged, the manipulator 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 Deutschland GmbH, are integrated into the industrial
robot, the user is responsible for ensuring that these components do not
adversely affect or disable safety functions.

NOTICE
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form, which may cause
damage to the electrical components. Do not put the robot controller in-
to 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 recommission-
ing:
General test:
It must be ensured that:

• The industrial robot is correctly installed and fastened in accordance

with the specifications in the documentation.
• There are no foreign bodies or defective or loose parts on the industri-
al 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 suffi-
ciently 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 all the safety-oriented functions to
ensure that they are working correctly:
Test of the safety-relevant mechanical and electromechanical compo-
nents:
The following tests must be performed prior to start-up and at least once
every 12 months unless otherwise determined in accordance with a work-
place risk assessment:
• Function of all connected EMERGENCY STOP devices
Press the EMERGENCY STOP device. A message must be displayed
on the teach pendant indicating that the EMERGENCY STOP has
been actuated. At the same time, no error message may be displayed
about the EMERGENCY STOP device.

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• Function of the enabling switches of all connected enabling devices

Move the robot in Test mode and release the enabling switch. The ro-
bot motion must be stopped. At the same time, no error message may
be displayed on the teach pendant about the enabling device.
The test must always be carried out for all enabling switches of a con-
nected enabling device.
If the state of the enabling device is configured at an output, the test
can also be performed via the output.
• Panic function of the enabling switches of all connected enabling devi-
ces
Move the robot in Test mode and press the enabling switch down fully.
The robot motion must be stopped. At the same time, no error mes-
sage may be displayed on the teach pendant about the enabling de-
vice.
The test must always be carried out for all enabling switches of a con-
nected enabling device.
If the state of the enabling device is configured at an output, the test
can also be performed via the output.
• Function of the keyswitch on the smartPAD (if used as teach pendant)
Turn the keyswitch to the right and then back again. There must be
no error message displayed on the smartPAD.
• Switch-off capability of the safety-oriented outputs
Switch robot controller off and then on again. After it is switched on,
no error message relating to a safety-oriented output may be dis-
played on the teach pendant.

In the case of incomplete start-up of the system, additional substitute

measures for minimizing risk must be taken and documented, e.g. in-
stallation of a safety fence, attachment of a warning sign, locking of the
main switch. Start-up is incomplete, for example, if not all safety func-
tions have yet been implemented, or if a function test of the safety func-
tions has not yet been carried out.

Test of the functional capability of the brakes:

For the industrial robot, a brake test is available which can be used to
check whether the brake of each axis applies sufficient braking torque.
The brake test ensures that any impairment of the braking function is de-
tected, e.g. due to wear, overheating, fouling or damage, thereby eliminat-
ing avoidable risks.
The brake test must be performed regularly, unless an application-specific
risk assessment has established that a malfunction of the mechanical
brakes will not result in inadmissibly high risks. Determination of the inter-
val at which the brake test is to be performed also constitutes part of the
risk assessment.
In the absence of a corresponding risk assessment, the following applies:

• The brake test must be carried out for each axis during start-up and
recommissioning of the industrial robot.
• The brake test must be performed daily during operation.

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5.4.5 Manual mode

General

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 opera-
tion. Setup work includes:
• Jog mode
• Teaching
• Program verification
The following must be taken into consideration in manual mode:
• New or modified programs must always be tested first in Manual Re-
duced Velocity mode (T1).
• The manipulator and its tooling must never touch or project beyond
the safety fence.
• Workpieces, tooling and other objects must not become jammed as a
result 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
safeguarded area.

Setup work in T1

If it is necessary to carry out setup work from inside the safeguarded

area, the following must be taken into consideration in the operating mode
Manual Reduced Velocity (T1):
• If it can be avoided, there must be no other persons inside the safe-
guarded area.
If it is necessary for there to be several persons inside the safeguar-
ded area, 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.
• Unexpected motions of the manipulator cannot be ruled out, e.g. in
the event of a fault. For this reason, an appropriate clearance must be
maintained between persons and the manipulator (including tool).
Guide value: 50 cm.
The minimum clearance may vary depending on local circumstances,
the motion program and other factors. The minimum clearance that is
to apply for the specific application must be decided by the user on
the basis of a risk assessment.

Setup work in T2

If it is necessary to carry out setup work from inside the safeguarded

area, the following must be taken into consideration in the operating mode
Manual High Velocity (T2):
• This mode may only be used if the application requires a test at a ve-
locity higher than that possible in T1 mode.
• Teaching is not permissible in this operating mode.
• Before commencing the test, the operator must ensure that the ena-
bling devices are operational.
• The operator must be positioned outside the danger zone.

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• There must be no-one present inside the safeguarded area. It is the

responsibility of the operator to ensure this.

5.4.6 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, or the requirements for collabora-
tive operation in accordance with EN ISO 10218 have been met.
• The defined working procedures are adhered to.
If the manipulator comes to a standstill for no apparent reason, the
danger zone must not be entered until an EMERGENCY STOP has been
triggered.

5.4.7 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 regula-
tions 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
operational state. Repair work includes troubleshooting in addition to the
actual repair itself.
The following safety measures must be carried out when working on the
industrial 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 addi-
tional safety measures 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 func-
tions or safeguards are deactivated during maintenance or repair work,
they must be reactivated immediately after the work is completed.

DANGER
Before work is commenced on live parts of the robot system, the main
switch must be turned off and secured against being switched on again.
The system must then be checked to ensure 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
Deutschland GmbH for this purpose.

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Cleaning and preventive maintenance work is to be carried out in accord-

Safety
ance with the operating instructions.

Robot controller

Even when the robot controller is switched off, parts connected to periph-
eral devices may still carry voltage. The external power sources must
therefore be switched off if work is to be carried out on the robot control-
ler.
The ESD regulations must be adhered to when working on components in
the robot controller.
Voltages in excess of 60 V can be present in various components for sev-
eral 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.

5.4.8 Decommissioning, storage and disposal

The industrial robot must be decommissioned, stored and disposed of in

accordance with the applicable national laws, regulations and standards.

5.4.9 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 “sin-
gle point of control” (SPOC).
Components:

• Tools for configuration of bus systems with online functionality

The implementation of additional safety measures may be required. This

must be clarified for each specific application; this is the responsibility of
the user of the system.

Since only the system integrator knows the safe states of actuators in the
periphery of the robot controller, it is his task to set these actuators to a
safe state.

T1, T2, CRR

In modes T1, T2 and CRR, a robot motion can only be initiated if an ena-
bling switch is held down.

Tools for configuration of bus systems

If these components have an online functionality, they can be used with

write access to modify programs, outputs or other parameters of the robot
controller, without this being noticed by any persons located inside the
system.
Such tools include:
• KUKA Sunrise.Workbench
• WorkVisual from KUKA
• Tools from other manufacturers

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Safety measure:
Safety

• In the test modes, programs, outputs or other parameters of the robot

controller must not be modified using these components.

5.5 Applied standards and directives

Name/Edition Definition

2006/42/EC:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)

2014/30/EU:2014 EMC Directive:

Directive 2014/30/EC of the European Parliament and of the Coun-
cil dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility

EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

EN ISO 13849-1:2015 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles
of design

EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation

EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction

EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1

EN 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles

EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments

EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments

EN 60204-1:2006/ Safety of machinery:

A1:2009
Electrical equipment of machines - Part 1: General requirements

EN 62061:2005 + Safety of machinery:

A1:2013 + A2:2015
Functional safety of safety-related electrical, electronic and pro-
grammable electronic control systems

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Planning
6 Planning

6.1 Overview

This is an overview of the most important planning specifications. The

precise planning depends on the application, the manipulator type, the
technology packages used and other customer-specific circumstances.
For this reason, the overview does not claim to be comprehensive.

Step Description Information

1 Electromagnetic compatibility (>>> 6.2 "Electromagnetic
(EMC) compatibility (EMC)"
Page 49)
2 Installation conditions for ro- (>>> 6.3 "Installation condi-
bot controller tions" Page 50)
3 Connection conditions (>>> 6.4 "Connection condi-
tions" Page 51)
4 Power supply connection
5 Safety interface X11 (>>> 6.6 "Interface X11"
Page 52)
6 Safety interface X11 default
connector pin allocation
7 KUKA Extension Bus inter- (>>> 6.7 "KUKA Extension
face X65 Bus X65" Page 57)
8 KUKA Line Interface X66 (>>> 6.8 "KUKA Line Inter-
face X66" Page 58)
9 Service interface X69 (>>> 6.9 "X69 KUKA Service
Interface" Page 59)
10 Media flange interface X650 (>>> 6.10 "Media flange in-
terface X650" Page 60)
11 Equipotential bonding (>>> 6.11 "PE equipotential
bonding" Page 60)
12 Performance Level (>>> 6.12 "Performance lev-
el" Page 61)

6.2 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 robot controller corresponds to EMC class A, Group 1, in accord-
ance 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 oc-
cur.

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6.3 Installation conditions

Dimensions

The robot controller can be installed in a 19" rack or as a standalone de-

vice. The specifications in the “Technical data” chapter (>>> 4 "Technical
data" Page 21) must be observed. If the robot controller is to be installed
in a 19" rack, the depth must be at least 600 mm.
If the robot controller is to be installed in a 19" rack, it must be fastened
in the rack by appropriate means (preferably angle plates) along the en-
tire side edge in order to prevent distortion of the housing.

Both sides of the robot controller must be accessible to the cooling air.
Clearance of 70 mm on each side.

Fig. 6-1: Dimensions

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Planning
Handle brackets

Fig. 6-2: Dimensions of handle brackets

6.4 Connection conditions

Power supply connection

The robot controller may only be connected to grounded-neutral power

supply systems.
Rated supply voltage 110 V/230 V AC, single-phase
Permissible tolerance of rated sup- Rated supply voltage ±10%
ply voltage
Mains frequency 50 Hz ± 1 Hz or 60 Hz ± 1 Hz
Rated power input 1 kVA, see rating plate
Thermal power dissipation 370 W
Mains-side fusing 2x 15 A slow-blowing (1x phase;
1x neutral conductor (optional))
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit.

CAUTION
If the robot controller is connected to a power system without a groun-
ded neutral, this may cause malfunctions in the robot controller and ma-
terial damage to the power supply units. Electrical voltage can cause in-
juries. The robot controller may only be operated with grounded-neutral
power supply systems.

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If use of a residual-current circuit-breaker (RCCB) is planned, we rec-

ommend the following RCCB: trip current difference 300 mA per robot
controller, 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 manipu-
lator.
When using smartPAD cable extensions, only two extensions may be
used. An overall cable length of 50 m must not be exceeded.

6.5 Power supply connection

Description

For connection to the mains, the robot controller is equipped with a 3-pole
socket for non-heating appliances. The robot controller must be connected
to the mains via the device connection cable included in the scope of sup-
ply.
The robot controller can be connected to the mains via the following de-
vice connection cables:
• with mains connector
• without mains connector

Infeed

• 110 V/230 V AC, single-phase, two-phase (with grounded neutral (as

symmetrical as possible) between the phases used)
• 50 Hz ± 1 Hz or 60 Hz ± 1 Hz

Fusing

• 2x 15 A slow-blowing, type C (1 (2)x phase; 1x neutral conductor (op-

tional))

6.6 Interface X11

Description

EMERGENCY STOP devices must be connected via interface X11 or

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

Wiring

Take the following points into consideration when wiring interface X11:
• System concept
• Safety concept

6.6.1 Contact diagram, connector X11

Description

The counterpart to interface X11 is a 50-contact D-Sub connector with a

male insert, type Harting F-95972.

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Fig. 6-3: Contact diagram, view from connection side

Outer diameter of cable: max. 12 mm

Recommended wire cross-section: AWG 20 (0.75 mm2)
In the cabling for the input signals and test signals in the system, suita-
ble 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, suit-
able measures must be taken to prevent a cross-connection between
the output signals of a channel (e.g. separate cabling).

6.6.2 X11 safety interface

The X11 safety interface is wired internally to the CCU_SR.

Connector pin allocation

Default settings
Signal Pin Designation Assignment Description Note
Test output A 1 External E- For 2-channel Triggers an
Input 1 A 2 STOP, channel connection of EMERGENCY
Safe input 1 A an EMERGEN- STOP
Test output B 10 (CIB_SR.1) External E- CY STOP de-
STOP, channel vice
Input 1 B 11
B max. 24 V
Test output A 3 Operator safe- For 2-channel Triggers a
Input 2 A 4 ty, channel A connection of a safety stop 1
Safe input 2 safety gate
Test output B 12 Operator safe- locking mecha-
(CIB_SR.2)
Input 2 B 13 ty, channel B nism
max. 24 V
Test output A 5 Safety stop 1, Input, safety Triggers a
Input 3 A 6 channel A stop 1 safety stop 1
Safe input 3 of all axes
Test output B 14 (CIB_SR.3) Safety stop 1,
Input 3 B 15 channel B

Test output A 7 - - -
Input 4 A 8 Safe input 4
Test output B 16 (CIB_SR.4) - - -
Input 4 B 17
Test output A 18 - - -
Input 5 A 19 Safe input 5
Test output B 28 (CIB_SR.5) - - -
Input 5 B 29

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Default settings
Signal Pin Designation Assignment Description Note
Test output A 20 - - -
Input 6 A 21 Safe input 6
Test output B 30 (CIB_SR.6) - - -
Input 6 B 31
Test output A 22 - - -
Input 7 A 23 Safe input 7
Test output B 32 (CIB_SR.7) - - -
Input 7 B 33
Output 12 A 34 E-STOP local Output, floating The contacts
35 channel A contacts from are closed if
internal EMER- the following
Output 12 B 45 E-STOP local GENCY STOP conditions are
46 channel B met:

• E-STOP on
smartPAD
not actu-
Safe output 12
ated
(CIB_SR.12)
• Controller
switched
on and op-
erational
The contacts
open if any
condition is not
met.
Output 13 A 36 Test mode, Output, floating The contacts
37 channel A contacts for are open when
Safe output 13 Test mode Test mode is
Output 13 B 47 (CIB_SR.13) Test mode, selected.
48 channel B

Output 14 A 38 Automatic Output, floating The contacts

39 mode, chan- contacts for are open when
Safe output 14 nel A Automatic Automatic
Output 14 B 49 (CIB_SR.14) Automatic mode mode is selec-
mode, chan- ted.
50
nel B
The assignments of the inputs and outputs are freely configurable. The
assignments specified in the table correspond to the default settings of the
safety configuration.
In the cabling for the input signals and test signals in the system, suita-
ble 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, suit-
able measures must be taken to prevent a cross-connection between
the output signals of a channel (e.g. separate cabling).

The voltage switched with the safe outputs must be generated by a

safely isolated PELV power supply according to EN 60950.

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6.6.3 Wiring example for E-STOP circuit and safeguard

Description

The EMERGENCY STOP devices are connected to X11 in the robot con-
troller.

EMERGENCY STOP

WARNING
The EMERGENCY STOP devices on the robot controller must be inte-
grated 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. 6-4: Wiring example: EMERGENCY STOP

6.6.4 Wiring example for safe inputs and outputs

Safe input

The switch-off capability of the inputs is monitored cyclically.

The inputs of the CIB_SR 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 float-
ing contact provided by the customer.

Fig. 6-5: Connection schematic for safe input

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1 Failsafe input CIB_SR

2 CIB_SR
3 Robot controller
4 Interface X11
5 Test output channel B
6 Test output channel A
7 Input X, channel A
8 Input X, channel B
9 System side
10 Floating contact
Test outputs A and B are fed with the supply voltage of the CIB_SR. Test
outputs A and B are sustained short-circuit proof. The test outputs must
only be used to supply the CIB_SR inputs, and for no other purpose.
The wiring example can be used to achieve compliance with SIL2 (DIN
EN 62061) and Cat. 3 (DIN EN 13849).

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 CIB_SRs 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. 6-6: 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)

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Planning
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 CIB_SR, 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 customer must be monitored externally for cross-connection.

Fig. 6-7: Connection schematic for safe output

1 CIB_SR
2 Robot controller
3 Interface X11, safe output
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 shown can be used to achieve compliance with SIL2
(DIN EN 62061) and Cat. 3 (DIN EN 13849).

6.7 KUKA Extension Bus X65

Description

Connector X65 is intended for connecting EtherCAT slaves outside the ro-
bot controller. The EtherCAT line is routed out of the robot controller.
The devices in the EtherCAT line must be configured with WorkVisual
and transferred to the controller using Sunrise Workbench.

Necessary equipment

• RJ45 connector

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Fig. 6-8: Pin assignment

• Recommended connecting cable: Ethernet-compatible, min. category

CAT 5
• Maximum cable cross-section: AWG22

Connector pin allocation X65 via CIB

Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
6 TPFI_N

6.8 KUKA Line Interface X66

Description

Connector X66 is intended for connecting an external computer for the

purpose of installation, programming, debugging and diagnosis.

Necessary equipment

• Connector RJ45

Fig. 6-9: Pin assignment

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Planning
• Recommended connecting cable: Ethernet-compatible, min. category
CAT 5e
• Maximum cable cross-section: AWG22

Connector pin allocation X66

Pin Description
1 TD+
2 TD-
3 RD+
6 RD-
4 C+
5 C-
7 D+
8 D-

6.9 X69 KUKA Service Interface

Description

Interface X69 is intended for connecting a notebook for the purpose of di-
agnosis, WorkVisual configuration, update, etc., via the KSI (KUKA Serv-
ice Interface). The service notebook does not have to be connected to the
shop network for this.

Necessary equipment

• RJ45 connector

Fig. 6-10: Pin assignment

• Recommended connecting cable: Ethernet-compatible, min. category

CAT 5
• Maximum cable cross-section: AWG22

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Connector pin allocation X69

Pin Description
1 TFPO_P
2 TFPO_N
3 TFPI_P
6 TFPI_I
- PE

6.10 Media flange interface X650

Description

Connector X650 is intended for supplying power to an external media

flange on the LBR iiwa wrist.

Necessary equipment

• Connector HAN 3A EMC

Fig. 6-11: Contact diagram, view from contact side

• Maximum cable cross-section: AWG22

Connector pin allocation X650

Pin Description
1 48 V
2 0 V
5 24 V
6 0 V
9 TD+
11 TD-
10 RD+
12 RD-
PE -

6.11 PE equipotential bonding

Description

The robot controller must be grounded by means of the PE equipotential

bonding rail at the installation site.

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Planning
6.12 Performance level

The safety functions of the robot controller conform to Category 3 and

Performance Level d according to EN ISO 13849-1.

6.12.1 PFH values of the safety functions

The safety values are based on a service life of 20 years.

The PFH value classification of the robot controller is only valid if all safe-
ty-relevant mechanical and electromechanical components of the industrial
robot are tested at least once every 12 months. The “Safety” chapter de-
scribes which components these are and how they are to be tested.
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 systems with coop-
erating robots 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 safety functions of the different controller
variants.
• The PFH values apply to all safety functions provided by KUKA Sun-
rise.

Further information about the available safety functions is contained in

the operating and programming instructions for the System Software.

Overview

Controller variant PFH values:

Robot controller PFH value
KUKA Sunrise Cabinet < 1 x 10-7

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Transportation
7 Transportation

7.1 Transportation with trolley

Preconditions

• The housing of the robot controller must be closed.

• No cables may be connected to the robot controller.

Procedure

• Transport the robot controller on a trolley.

Fig. 7-1: Transportation with trolley

7.2 Transportation without trolley

Preconditions

• The housing of the robot controller must be closed.

• No cables may be connected to the robot controller.

Procedure

• Transport the robot controller using the carrying handles.

Fig. 7-2: Transportation without trolley

1 Carrying handles

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Start-up and recommissioning

8 Start-up and recommissioning

8.1 Overview

This is an overview of the most important steps during start-up. The pre-
cise sequence depends on the application, the manipulator type, the tech-
nology packages used and other customer-specific circumstances.
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 in-
2 Install the manipulator mounting base (mount- structions 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

Step Description Information

4 Carry out a visual inspection of the -
robot controller.
5 Make sure that no condensation has -
formed in the robot controller.
6 Install the robot controller. (>>> 8.2 "Installing the robot control-
ler" Page 66)
7 Connect the connecting cables. (>>> 8.3 "Connecting the connecting
cables" Page 66)
8 Plug in the KUKA smartPAD. (>>> 8.4 "Plugging in the KUKA
smartPAD" Page 67)
9 Connect the equipotential bonding. (>>> 8.5 "Connecting the PE equipo-
tential bonding" Page 67)
10 Reverse the battery discharge protec- (>>> 8.6 "Reversing the battery dis-
tion measures. charge protection measures"
Page 67)
11 Configure and connect interface X11. (>>> 8.7 "Configuring and connecting
connector X11" Page 68)
12 Connect the robot controller to the (>>> 8.8 "Connecting the robot con-
power supply. troller to the power supply" Page 68)
13 Switch on the robot controller. (>>> 8.9 "Switching on the robot con-
troller" Page 69)
14 Check the safety equipment. Detailed information is contained in
the operating and assembly instruc-
tions for the robot controller, in the
“Safety” chapter.
15 Configure the inputs/outputs between Detailed information can be found in
the robot controller and the periphery. the field bus documentation.

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8.2 Installing the robot controller

Description

The robot controller can be installed in a 19" rack or as a standalone de-

vice.

Preconditions

• If the robot controller is to be installed in a 19" rack, the depth must

be at least 700 mm.
• Both sides of the robot controller must be accessible to the cooling air.

Procedure

1. Check the robot controller for any damage caused during transporta-
tion.
2. Install the robot controller, preferably in the horizontal position. If the
robot controller is installed in the vertical position, both sides must al-
ways be accessible to the cooling air.

8.3 Connecting the connecting cables

Overview

A standard cable set with the following basic equipment is supplied with
the robot system:
• Connecting cable
• Device connection cable
The following cables may be provided for additional applications:
• Peripheral cables

Procedure

• Plug connecting cable connector X21 into the control box.

Connector pin allocation X21

Pin Description
1 48 V DC out1
2 0 V
3 48 V DC out2
4 0 V
5 +24V network
6 GND
9 TPFO_P
10 TPFI_P
11 TPFO_N
12 TPFI_N

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Start-up and recommissioning

8.4 Plugging in the KUKA smartPAD

Procedure

• Plug the KUKA smartPAD to X19 on the robot controller.

If the smartPAD is disconnected, an EMERGENCY STOP is triggered.

Connector pin allocation X19

Pin Description
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

8.5 Connecting the PE equipotential bonding

Procedure

1. Ground the robot controller at the installation site.

2. Carry out a ground conductor check for the entire robot system in ac-
cordance with DIN EN 60204-1.

8.6 Reversing the battery discharge protection measures

Description

To prevent the batteries from discharging before the controller has been
started up for the first time, the robot controller is supplied with connector
X305 disconnected from the CCU_SR.

Procedure

• Plug connector X305 into the CCU_SR.

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Fig. 8-1: Battery discharge protection X305

1 Connector X305 on the CCU_SR

8.7 Configuring and connecting connector X11

Precondition

• The robot controller is switched off.

Procedure

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

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

NOTICE
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 occur.

8.8 Connecting the robot controller to the power supply

8.8.1 Connecting the robot controller to the power supply with a mains con-
nector

Precondition

• The robot controller is switched off.

• The power cable is de-energized.

Procedure

1. On the robot controller, plug in the connector for non-heating applian-

ces for the device connection cable.
2. Connect the robot controller to the mains via the mains connector.

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Start-up and recommissioning

8.8.2 Connecting the robot controller to the power supply without a mains
connector

Precondition

• The robot controller is switched off.

• The power cable is de-energized.
• Connection to the power supply must be carried out in accordance
with the applicable national regulations.
• The power supply connection and the mains connector must be de-
signed in accordance with the power data of the robot controller.
(>>> "Power supply connection" Page 21)

Procedure

1. On the robot controller, plug in the connector for non-heating applian-

ces for the device connection cable.
2. Connect the robot controller to the mains via the mains connector.
3. Connect the robot controller to a grounded-neutral power supply sys-
tem in accordance with (>>> Fig. 8-2).
• Green/yellow (GNYE) to the PE of the power supply system
• Light blue (BU) to the neutral conductor of the power supply sys-
tem
• Black (BK) to the live cable of the power supply system

Fig. 8-2: Power supply connection

8.9 Switching on the robot controller

Preconditions

• The manipulator has been installed in accordance with the operating

instructions.
• All electrical connections are correct and the energy levels are within
the specified limits.
• The housing of the robot controller must be closed.
• The peripheral devices are correctly connected.
• It must be ensured that no persons or objects are present within the
danger zone of the manipulator.
• All safety devices and protective measures are complete and fully
functional.
• The internal temperature of the robot controller must have adapted to
the ambient temperature.

Procedure

1. Release the E-STOP device on the smartPAD.

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2. Switch on the main switch.

The control PC begins to run up (load) the operating system and the
control software.

Information about operator control of the manipulator using the smart-

PAD can be found in the operating and programming instructions for the
KUKA System Software.

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Operation
9 Operation

9.1 KUKA smartPAD teach pendant

9.1.1 Front view

Function

The smartPAD is the teach pendant for the robot. The smartPAD has all
the operator control and display functions required for operation.
The smartPAD has a touch screen: the smartHMI can be operated with a
finger or stylus. An external mouse or external keyboard is not necessary.

Overview

Fig. 9-1: KUKA smartPAD, front view

Item Description
1 Button for disconnecting the smartPAD

2 Keyswitch
The connection manager is called by means of the keyswitch.
The switch can only be turned if the key is inserted.
The connection manager is used to change the operating mode.

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Item Description
3 EMERGENCY STOP device
The robot can be stopped in hazardous situations using the
EMERGENCY STOP device. The EMERGENCY STOP device
locks itself in place when it is pressed.
4 6D mouse
The 6D mouse can be used to move the robot manually.

5 Jog keys
The jog keys can be used to move the robot manually.

6 Key for setting the override

7 Main menu key

The main menu key shows and hides the main menu on the
smartHMI.

8 User keys
The function of the user keys is freely programmable. Uses of
the user keys include controlling peripheral devices or triggering
application-specific actions.

9 Start key
The Start key is used to start a program. The Start key is also
used to manually address frames and to move the robot back
onto the path.

10 Start backwards key

No function
11 STOP key
The STOP key is used to stop a program that is running.
12 Keyboard key
No function

The following applies to the jog keys, the user keys and the Start, Start
backwards and STOP keys:
• The current function is displayed next to the key on the smartHMI.
• If there is no display, the key is currently without function.

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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
Identification
Identification plate
plate
The Start key is used to start a program. The Start
Start key key is also used to manually address frames and to
move the robot back onto the path.

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Element Description
The enabling switch has 3 positions:

• Not pressed
• Center position
Enabling • Fully pressed (panic position)
switch The enabling switch must be held in the center posi-
tion in operating modes T1, T2 and CRR in order to
be able to jog the manipulator.
As standard, the enabling switch has no function in
Automatic mode.
The USB connection is used for archiving data, for
USB connec- example.
tion
Only for FAT32-formatted USB sticks.

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Maintenance
10 Maintenance
Description

Maintenance work must be performed at the specified maintenance inter-

vals after commissioning at the customer’s plant.

Maintenance symbols

Tighten screw/nut

Check component, visual inspection

Clean component

Exchange battery

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Observe the ESD guidelines.

Fig. 10-1: Maintenance diagram

Interval Item Activity

1 year 4 Check the utilized relay outputs of the CCU_SR for
correct functioning. (>>> 10.1 "Checking CCU_SR
relay outputs" Page 76)
- Perform function test of all enabling switches on
the smartPAD.
1 year at 1 Depending on installation conditions and degree of
the latest fouling, clean the protective grille and fan with a
brush.

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Interval Item Activity

5 years 2 Exchange the motherboard battery. (>>> 11.4 "Ex-
changing the motherboard battery" Page 82)
5 years 1 Exchange the fan. (>>> 11.7 "Exchanging the fans"
(with 3-shift Page 85)
operation)
As indica- 3 Exchange the batteries. (>>> 11.6 "Exchanging the
ted by the batteries" Page 83)
battery
monitoring
Once an activity from the maintenance list has been carried out, a visual
inspection must be made, with special attention to the following points:
• Check that fuses, contactors, plug-in connections and boards are fitted
securely.
• Check cabling for damage.
• Check PE equipotential bonding connection.
• Check all system components for wear and damage.

10.1 Checking CCU_SR relay outputs

Activity

Check the function of output 12 (default: “Local E-STOP”).

Procedure

• Actuate the configured function of output 12 (default: Press the local

EMERGENCY STOP device).

Activity

Check the function of output 13 (default: “Test mode”).

Procedure

• Actuate the configured function of output 13 (default: Actuate Test

mode).

Activity

Check the function of output 14 (default: “Automatic mode”).

Procedure

• Actuate the configured function of output 14 (default: Actuate Automat-

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

10.2 Cleaning the robot controller

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• The controller has been shut down.
• The power cable is de-energized.

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Maintenance
WARNING
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.

Work regulations

• The manufacturer’s instructions must be observed when using clean-

ing agents for cleaning work.
• It must be ensured that no cleaning agents enter electrical compo-
nents.
• 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.

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Repair
11 Repair

11.1 Repair and procurement of spare parts

Repair

Repairs to the robot controller may only be carried out by KUKA

Customer Support personnel or by customers who have taken part in a
relevant course of training.
Repairs within modules may only be carried out by specially trained KUKA
Customer Support personnel.

Procurement of spare parts

The article numbers of the spare parts are listed in the spare parts cata-
log.
KUKA Customer Support supplies the following types of spare parts for re-
pairs 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 Customer Support.

A “Robot Repair Card” is supplied with the exchange parts. The Repair
Card must be completed and returned to KUKA Customer Support.

11.2 Opening the housing cover

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Observe the ESD guidelines.

Procedure

1. Unscrew the housing cover screws.

2. Open the housing cover.

Fig. 11-1: Housing cover screws

1 Housing cover screws

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11.3 Exchanging the motherboard

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Observe the ESD guidelines.

Procedure

1. Loosen the housing cover screws and open the cover.

Fig. 11-2: Opening the housing cover

1 Housing cover screws

2. Unplug the fan connections.

Fig. 11-3: Connections for fans

1 Connector for fans

2 Connector for motherboard CPU fan

3. Remove the fastening screws from the fan holder.

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Repair
Fig. 11-4: Fastening the fans

1 Fastening of the fan holder

4. Remove the fan holder with the fans.

5. Remove all PC plug-in cards.
6. Disconnect all motherboard connections.
7. Remove motherboard fastening screws (Torx).

Fig. 11-5: Motherboard fastening

1 Motherboard fastening

8. Remove motherboard from the housing and place it on a suitable

ESD-compliant support.
9. Insert new motherboard and screw it in place.
10. Screw in motherboard fastening screws (Torx).
11. Plug in all motherboard connections.
12. Install the fan holder with the fans.
13. Screw in the fastening screws of the fan holder.
14. Plug in the fan connections.
15. Install the PC plug-in cards.
16. Close the housing cover.

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11.4 Exchanging the motherboard battery

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Observe the ESD guidelines.

Procedure

1. Open the housing cover. (>>> 11.2 "Opening the housing cover"
Page 79)
2. Unlock the locking mechanism of the lithium button cell and remove
the button cell.

Fig. 11-6: Lithium button cell

1 Lithium button cell

2 Locking mechanism of lithium button cell

3. Insert the new lithium button cell and click the locking mechanism into
place.
4. Close the housing cover.

11.5 Exchanging the hard drive

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Observe the ESD guidelines.

Procedure

1. Open the housing cover.

(>>> 11.2 "Opening the housing cover" Page 79)
2. Unplug the hard drive connections (power supply and data cable).

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Repair
Fig. 11-7: Connection of hard drive

1 Hard drive connections

3. Remove the hard drive retaining screws.

Fig. 11-8: Hard drive fastening

1 Hard drive fastening

4. Remove the hard drive.

5. Plug the connections to the new hard drive.
6. Fasten the new hard drive to the housing.
7. Close the housing cover.

11.6 Exchanging the batteries

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Observe the ESD guidelines.

Procedure

1. Open the housing cover. (>>> 11.2 "Opening the housing cover"
Page 79)
2. Unfasten the Velcro strips.

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3. Unplug the battery connection cables.

Fig. 11-9: Battery blocks, fastening and connections

1 Velcro strip for battery fastening

2 Battery connection cables

4. Take out both battery blocks.

The battery blocks must both be exchanged together.

5. Insert new battery blocks.

6. Fasten the Velcro strips.
7. Plug in the battery connection cables in accordance with the cable la-
bels.

Fig. 11-10: Battery polarity

1 Connection for G3.2

2 Connection for G3.1

8. Close the housing cover.

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Repair
Storage

NOTICE
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.
If the storage temperature is between +30 °C and +40 °C, the batteries
must be recharged every 3 months.

11.7 Exchanging the fans

Precondition

• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Observe the ESD guidelines.

Procedure

1. Open the housing cover. (>>> 11.2 "Opening the housing cover"
Page 79)
2. Remove the fastening screws from the fan holder.

Fig. 11-11: Fastening of fans

1 Fastening of the fan holder

3. Unplug the fan connections.

Fig. 11-12: Connections for fans

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Repair KUKA Sunrise Cabinet

1 Connector for fans

2 Connector for motherboard CPU fan

4. Remove the fan holder with the fans.

5. Unscrew the inner and outer fan grilles and screw them to the new
fans.
6. Install and fasten the new fans with the fan holder.
7. Plug in the connecting cables.

11.8 Installation of KUKA Sunrise.OS

Further information is contained in the operating and programming in-

structions for KUKA Sunrise.OS.

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Troubleshooting
12 Troubleshooting

12.1 LED display on Cabinet Control Unit, Small Robot

Overview

Fig. 12-1: CCU_SR LED display

Item Designation Color Description Remedy

1 PHY4 Green Off = fault Exchange CCU_SR module.
On = OK -
Flashing = OK -
2 SW_P0 Green Off = fault Exchange CCU_SR module.
On = OK -
Flashing = OK -
3 RUN SION Green Off = Init (after switching -
on)
EtherCat
Safety nodes On = operational (normal -
state)
Flashing at 2.5 Hz = Pre- -
Op (intermediate state on
startup)
Single signal = Safe Op -
Flashing at 10 Hz = boot -
(for firmware update)

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Troubleshooting KUKA Sunrise Cabinet

Item Designation Color Description Remedy

4 L/A Green • Off = no physical con- -
KSB nection. Network cable
not plugged in
5 L/A Green
• On = physical connec-
100 Mbit
KSB KPC-MC tion. Network cable
Orange plugged in
1 Gbit • Flashing = data traffic
on the line
6 PWR/3.3V Green Off = no supply voltage • Check fuse F17.3.
present
Power for the • Jumper plug X308
CIB_SR present.
• Check fuse F308.
• With external supply via
X308: check the exter-
nal power supply (rated
voltage 24 V).
On = supply voltage present -
7 PWR/2.5V Green Off = no supply voltage • Check fuse F17.3.
present
Power for the • Jumper plug X308
CIB_SR present.
• Check fuse F308.
• With external supply via
X308: check the exter-
nal power supply (rated
voltage 24 V).
On = supply voltage present -
8 PWR/1.2V Green Off = no supply voltage • Check fuse F17.3.
present
Power for the • Jumper plug X308
CIB_SR present.
• Check fuse F308.
• With external supply via
X308: check the exter-
nal power supply (rated
voltage 24 V).
On = supply voltage present -
9 PWRS/3.3V Green Off = no supply voltage • Check fuse F17.3.
present
• If the LED PWR/3.3V
lights up, exchange the
CCU_SR module.
On = power supply present -

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 KUKA Sunrise Cabinet

Troubleshooting
Item Designation Color Description Remedy
10 STAS2 Orange Off = no supply voltage • Check fuse F17.3.
present
Safety node B • If the LED PWR/3.3V
lights up, exchange the
CCU_SR 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 purpo-
ses, disconnect the cables
at X309, X310, X312 and
switch the controller off and
back on again. If the error
recurs, exchange the mod-
ule.
11 STAS1 Orange Off = no supply voltage • Check fuse F17.3.
present
Safety node A • If the LED PWR/3.3V
lights up, exchange the
CCU_SR 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 purpo-
ses, disconnect the cables
at X309, X310, X312 and
switch the controller off and
back on again. If the error
recurs, exchange the mod-
ule.
12 FSoE Green Off = not active -
Safety proto- On = operational -
col of the Flashing = fault code (inter- -
EtherCat con- nal)
nection
13 L/A Green • Off = no physical con- -
KCB nection. Network cable
not plugged in.
14 KSB smart- Green
• On = physical connec-
PAD_MC 100 Mbit
tion
Orange
• Flashing = data traffic
1 Gbit
on the line
15 L/A Green
KSB

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Troubleshooting KUKA Sunrise Cabinet

Item Designation Color Description Remedy

16 RUN CIB_SR Green Off = Init (after switching -
on)
EtherCat
ATμC I/O On = operational (normal -
node state)
Flashing at 2.5 Hz = Pre- -
Op (intermediate state on
startup)
Single signal = Safe Op -
10 Hz = boot (for firmware -
update)
17 STA1 Orange Off = no supply voltage • Check fuse F17.3.
(CIB_SR) present
• If the LED PWR/3.3V
μC I/O node lights up, exchange the
CCU_SR module.
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU_SR module.
nal)
18 STA2 Orange Off = no supply voltage • Check infeed at X1.
present
FPGA node • If the LED PWR/3.3V
lights up, exchange the
CCU_SR module.
Flashing at 1 Hz = normal
state
Flashing at 10 Hz = boot
phase
Flashing = fault code (inter- Exchange CCU_SR module.
nal)
19 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 back-
up
20 PS1 Green Off = no supply voltage • Check infeed at X1 (rat-
present ed voltage 27.1 V).
Voltage, Pow-
er Supply 1 • Drive bus switched off
(short battery (BusPowerOff state)
backup) On = power supply present -
21 PS2 Green Off = no supply voltage • Check infeed at X1.
present
Voltage, Pow- • Controller in Sleep state
er Supply 2 On = power supply present -
(medium bat-
tery backup)

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Troubleshooting
Item Designation Color Description Remedy
22 PS3 Green Off = no supply voltage On = power supply present
present
Voltage, Pow-
er Supply 3 On = power supply present -
(long battery
backup)
23 STA1 Orange Off = no supply voltage • Check infeed at X1.
(PMB_SR) present
• If the LED PWR/5V
μC USB lights up, exchange the
CCU_SR module.
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU_SR module.
nal)
24 PWR/5V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V).
Power supply
for PMB_SR
25 Temp Fault Red Off = no overtemperature at -
ballast resistor R1
On = overtemperature at • Check connector X501.
ballast resistor R1
• Check control box cool-
ing.
• Check temperature sen-
sor (central position on
ballast resistor R1 on
the right-hand inner
wall).
26 PWR_+12V5 Green Off = brake chopper power • Check connector X500.
supply not present
• Check connector on the
low-voltage power sup-
ply unit.
On = brake chopper power -
supply present
27 Fuse LEDs Red Off = fuse OK -
The LEDs in- On = fuse defective Exchange defective fuse.
dicate the sta-
tus of the
fuses.

12.2 Fuses on the Cabinet Control Unit, Small Robot

Overview

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.

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Troubleshooting KUKA Sunrise Cabinet

Fig. 12-2: Arrangement of the fuses

The fuse ratings printed on the board must be observed.

Item Designation Description Fuse rating

1 F306 smartPAD power supply 2 A
2 F302 Not used 5 A
3 F3-1 Not used 15 A
4 F5-1 Not used 15 A
5 F4-1 KPC with battery backup 10 A
6 F307 Not used 2 A
7 F4-2 Not used 2 A
8 F22 Not used 7.5 A
9 F5-2 Not used 7.5 A
10 F3-2 Not used 7.5 A
11 F17-2 Inputs CCU_SR 2 A
12 F17-4 Safe inputs and relays 2 A
CCU_SR
13 F17-1 Contactor outputs 1 … 4 5 A
CCU_SR
14 F17-3 Logic CCU_SR 2 A
15 F14 Not used 7.5 A
16 F6 24 V without battery backup 7.5 A
(optional)
17 F21 PDS power supply 3 A
18 F305 Battery infeed 15 A
19 F301 Without battery backup, spare 10 A
20 F15 Power supply unit fan 2 A
21 F308 External power supply 7.5 A

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 KUKA Sunrise Cabinet

Troubleshooting
12.3 Low-voltage power supply unit fuses

Overview

Fig. 12-3: Fuses

Item Designation Description Fuse rating

1 F1 80 V fusing 5 A
2 F2 80 V fusing 7.5 A

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Decommissioning, storage and disposal

13 Decommissioning, storage and disposal

13.1 Decommissioning

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
decommissioning, it is prepared for storage or for transportation to a differ-
ent location.
Following its removal, the robot controller may only be transported with lift-
ing 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 stor-
age.
• Select a storage location in which the packaging materials cannot be
damaged.
• Only store the robot controller indoors.

Procedure

1. Clean the robot controller. No dirt may remain on or in the robot con-
troller.
2. Inspect the robot controller, both internally and externally, for damage.
3. Remove batteries and store in accordance with the manufacturer’s in-
structions.
4. Remove any foreign bodies.
5. Remove any corrosion expertly.
6. Attach all covers to the robot controller and check that the seals are
correctly in place.
7. Seal off electrical connections with suitable covers.

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Decommissioning, storage and disposal KUKA Sunrise Cabinet

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 dis-
mantled, and the materials can be disposed of properly by type.
The following table provides an overview of the materials used in the ro-
bot controller. Some of the plastic components are marked with a material
designation and must be disposed of accordingly.
As the end user, the customer is legally required to return depleted bat-
teries. 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 ordi-
nary 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 Notice
ponent
Steel-plate compo- Screws and washers, -
nents robot controller hous-
ing
PUR Cable sheaths -
Plastic parts Flexible tube -
Cable Electrical cables, -
wires, copper
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
Mains filter
Fans
Adhesive labels
Lead battery

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 KUKA Sunrise Cabinet

KUKA Service
14 KUKA Service

14.1 Requesting support

Introduction

This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.

Information

The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ 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 modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
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

hesitate to contact us if you have any questions.

Argentina
Ruben Costantini S.A. (Agentur)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

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KUKA Service KUKA Sunrise Cabinet

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

Belgium
KUKA Automatisering + Robots N.V.
Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
[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

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KUKA Service
Germany
KUKA Deutschland GmbH
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
[email protected]
www.kuka.com

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 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

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KUKA Service KUKA Sunrise Cabinet

Japan
KUKA Japan K.K.
YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
[email protected]

Canada
KUKA Robotics Canada Ltd.
2865 Argentia Road, Unit 4-5
Mississauga
Ontario L5N 8G6
Canada
Tel. +1 905 858‑5852
Fax +1 905 858-8581
[email protected]
www.kukarobotics.ca

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]

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KUKA Service
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 CEE GmbH
Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 732 784 752 0
Fax +43 732 793 880
[email protected]
www.kuka.at

Poland
KUKA CEE GmbH Poland
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

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KUKA Service KUKA Sunrise Cabinet

Russia
KUKA Russia OOO
1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
[email protected]

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 CEE GmbH
Linz, Zweigniederlassung Schweiz
Heinrich Wehrli-Strasse 27
5033 Buchs
Switzerland
Tel. +41 62 837 43 20
[email protected]

Slovakia
KUKA CEE GmbH
organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
[email protected]

Spain
KUKA Iberia, S.A.U.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
[email protected]

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KUKA Service
South Africa
Jendamark Automation LTD (Agentur)
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 Automation Taiwan Co. Ltd.
1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
[email protected]

Thailand
KUKA (Thailand) Co. Ltd.
No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
[email protected]

Czech Republic
KUKA Roboter CEE GmbH
organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
[email protected]

Hungary
KUKA HUNGÁRIA Kft.
Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

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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.kuka.com

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

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Index Declaration of incorporation.....................27, 28

Decommissioning..................................... 47, 95
19" rack.................................................... 50, 66
defective fuses................................................91
2006/42/EC:2006............................................ 48
Device connection cable................................ 14
2014/30/EU:2014............................................ 48
Dimensions..................................................... 24
6D mouse....................................................... 72
Dimensions, handle brackets......................... 25
95/16/EC......................................................... 48
Dimensions, smartPAD holder....................... 25
Disposal............................................. 47, 95, 96
Documentation, industrial robot....................... 7
A Dual NIC card...................................................8
Accessories.............................................. 11, 27 Dynamic testing.............................................. 56
ANSI/RIA R.15.06-2012................................. 48
Applied standards and directives...................48
AUT.................................................................29
Automatic........................................................ 29
E
EA..................................................................... 8
Automatic mode..............................................46
EC declaration of conformity......................... 28
Axis range.......................................................29
EDS...................................................................8
Electromagnetic compatibility (EMC)............. 48
Electromagnetic compatibility (EMC):............ 48
B Electromagnetic compatibility, EMC...............49
Basic data.......................................................21 EMC.................................................................. 8
Batteries..........................................................14 EMC Directive.......................................... 28, 48
Batteries, exchanging..................................... 83 EMERGENCY STOP......................................72
Battery discharge protection, reversing......... 67 EMERGENCY STOP device....................33–35
Brake defect................................................... 40 EMERGENCY STOP devices to X11............ 55
Braking distance............................................. 29 EMERGENCY STOP wiring example............55
EMERGENCY STOP, external................ 33, 35
EN 60204-1:2006/A1:2009............................. 48
C EN 61000-6-2:2005........................................ 48
Cabinet Control Unit LED display..................87 EN 61000-6-4:2007 + A1:2011...................... 48
Cabinet Control Unit Small Robot, fuses...... 91 EN 614-1:2006+A1:2009................................48
Cabinet Control Unit, Small Robot................ 13 EN 62061:2005 + A1:2013 + A2:2015..........48
Cabinet Interface Board, Small Robot.... 13, 23 EN ISO 10218-1:2011.................................... 48
Cable lengths........................................... 23, 52 EN ISO 12100:2010....................................... 48
CCU_SR.....................................................8, 13 EN ISO 13849-1:2015....................................48
CCU_SR functions......................................... 13 EN ISO 13849-2:2012....................................48
CCU_SR LED display, overview....................87 EN ISO 13850:2015....................................... 48
CCU_SR relay outputs, checking.................. 76 Enabling device........................................33, 34
CE mark..........................................................28 Enabling device, external........................ 33, 36
Charge............................................................ 14 Enabling switch........................................ 73, 74
CIB_SR.......................................................8, 23 Enabling switches...........................................34
CIB_SR inputs................................................ 23 Environmental conditions............................... 21
CIB_SR outputs..............................................23 Exhaustive discharge, battery................. 22, 85
CIB_SR, safe input.........................................55 External voltage..............................................24
CIB_SR, safe output...................................... 57
Cleaning work.................................................47
Connecting cables....................................11, 27 F
Connecting cables, connecting...................... 66 Fans, exchange.............................................. 85
Connection conditions.................................... 51 Faults.............................................................. 41
Connection panel............................................12 Filter mats.......................................................18
Control PC................................................11, 12 Function test................................................... 43
Control unit..................................................... 22 Fusing............................................................. 52
Cooling............................................................18
Cooling circuit................................................. 18
CRR................................................................ 30
G
General safety measures............................... 40
D
Danger zone................................................... 30
Declaration of conformity............................... 28
H

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Hand-held control panel...........................11, 27 Mains filter...................................................... 14

Hard drive, exchanging.................................. 82 Maintenance............................................. 46, 75
Maintenance symbols.....................................75
Manipulator..............................8, 11, 27, 30, 33
I Manipulator cable........................................... 14
Identification plate...........................................73 Manual mode..................................................45
Industrial robot................................................27 Material designation....................................... 96
Infeed.............................................................. 52 Mode selection............................................... 37
Installation conditions..................................... 50 Monitoring, physical safeguards.....................35
Installation of KUKA Sunrise.OS................... 86 Motherboard battery, exchange..................... 82
Installing the robot controller......................... 66 Motherboard D3076-K.................................... 15
Intended use.............................................. 9, 27 Motherboard D3236-K.................................... 16
Interface X11.................................................. 52 Motherboard D3445-K..............................17, 18
Interface X650, media flange.........................60 Motherboard, exchanging...............................80
Interfaces........................................................ 14 Motherboards..................................................15
Interfaces, control PC.....................................15
Introduction....................................................... 7
IT security....................................................... 42 N
Non-safety-oriented functions.........................37

J
Jog keys......................................................... 72 O
Jog mode........................................................39 Opening the housing cover............................79
Operation........................................................ 71
Operator..........................................................29
K Operator safety........................................ 33, 35
KCB...................................................................8 Operators........................................................ 32
KEB...................................................................8 Options..................................................... 11, 27
KEI.................................................................... 8 Overload......................................................... 40
Keyboard key..................................................72 Overview of the robot system........................ 11
KLI.....................................................................8
KOI....................................................................8
KONI................................................................. 8 P
KPC...................................................................8 Panic position................................................. 34
KSB...................................................................8 PC interfaces............................................ 15–17
KSI..............................................................8, 59 PE equipotential bonding............................... 60
KSP_SR............................................................8 PE equipotential bonding, connecting........... 67
KSS...................................................................8 PELV power supply unit.................................24
KUKA Customer Support............................... 97 Performance level...........................................61
KUKA Extension Bus X65............................. 57 Performance Level......................................... 29
KUKA Line Interface X66X66........................ 58 Peripheral cables............................................14
KUKA Service.................................................97 Personnel........................................................31
KUKA Service Interface, X69........................ 59 PFH values..................................................... 61
KUKA smartPAD................................22, 30, 71 PL....................................................................61
KUKA Sunrise Cabinet................................... 11 Planning.......................................................... 49
KUKA Sunrise Cabinet overview................... 11 Planning, overview......................................... 49
Plant integrator............................................... 31
Plates and labels............................................26
L PMB_SR........................................................... 8
Labeling.......................................................... 39 Power failure...................................................14
Liability............................................................ 27 Power Management Board, Small Robot......13
Low-voltage power supply unit...................... 13 Power supply connection............................... 52
Low-voltage power supply unit fuses............ 93 Power supply connection, technical data....21,
Low Voltage Directive.....................................28 51
Power supply with battery backup.................13
Power supply with mains connector,
connection...................................................... 68
M Power supply without battery backup............13
Machinery Directive..................................28, 48
Power supply without mains connector,
Main menu key...............................................72
connection...................................................... 69

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Power supply, connecting.............................. 68 Storage..................................................... 47, 95

Power switched off......................................... 14 Storage of batteries........................................85
Preventive maintenance work........................ 47 Support request.............................................. 97
Procurement of spare parts........................... 79 Switching on the robot controller...................69
Product description......................................... 11 System integrator.............................. 28, 31, 32
Protective equipment......................................39
Purpose.............................................................9
T
T1....................................................................31
R T2....................................................................31
Reaction distance........................................... 29 Target group..................................................... 9
Recommissioning..................................... 42, 65 Technical data.................................................21
Repair....................................................... 46, 79 Terms used....................................................... 8
Robot controller........................................ 11, 27 Terms, safety.................................................. 29
Robot controller, cleaning...............................76 Touch screen.................................................. 71
Trademarks....................................................... 8
Training............................................................. 9
S Transportation.......................................... 42, 63
Safe operational stop, external............... 33, 36 Transportation with trolley.............................. 63
Safeguard to X11........................................... 55 Transportation without trolley......................... 63
Safeguards, external...................................... 39 Troubleshooting.............................................. 87
Safely isolated................................................ 24
Safety..............................................................27
Safety-oriented functions................................33 U
Safety-oriented stop reactions....................... 36 USB...................................................................8
Safety functions.............................................. 28 USB connection..............................................73
Safety instructions............................................ 7 Use, contrary to intended use....................... 27
Safety interface, X11...................................... 53 Use, improper................................................. 27
Safety of machinery....................................... 48 User.......................................................... 29, 31
Safety stop......................................................30 User keys........................................................72
Safety stop 0.................................................. 30
Safety stop 1.................................................. 30
Safety stop 1 (path-maintaining)....................30 V
Safety stop, external................................33, 35 Velocity monitoring, T1...................................38
Safety zone........................................30, 32, 33
Safety, legal framework..................................27
SATA connections............................................ 8
Service life...................................................... 30
W
Warnings........................................................... 7
Single point of control.................................... 47
Workspace......................................... 29, 32, 33
Slot assignment, motherboard D3076-K....... 16
Slot assignment, motherboard D3236-K....... 17
Slot assignment, motherboard D3445-K....... 18
smartPAD........................................... 30, 41, 71 X
Cable extensions................................ 23, 52 X11, configuring and connecting....................68
smartPAD cable..............................................14 X11, connector pin allocation.........................53
smartPAD, plugging in....................................67 X11, contact diagram..................................... 52
Software....................................................11, 27 X11, safety interface.......................................53
Software limit switches...................................39 X21, connector pin allocation........................ 66
SPOC..............................................................47 X65..................................................................57
SSD...................................................................8 X650................................................................60
Start-up.....................................................42, 65 X650, connector pin allocation...................... 60
Start-up, overview...........................................65 X69, KSI......................................................... 59
Start backwards key.......................................72
Start key................................................... 72, 73
Stop category 0.............................................. 30
Stop category 1.............................................. 30
Stop category 1 (path-maintaining)............... 31
STOP key....................................................... 72
Stop reactions, safety-oriented...................... 36
Stopping distance.................................... 29, 33

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