Page 1 KUKA Robot Group Controller KR C2 edition05 Operating Instructions Industrial automation Elincom Group European Union: www.hmi4u.com Issued: 11.07.2007 Version: 3.3 Russia: www.elinc.ru V3.3 11.07.200...
Page 2 This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the KUKA ROBOT GROUP. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work.
Page 3: Table Of Contents
2.3.8 Digital servo-electronics (DSE-IBS-C33) ..............2.3.9 KUKA VGA card (KVGA) ................... 2.3.10 Batteries ........................Description of the KUKA Control Panel (KCP) ............... 2.4.1 Front view ........................2.4.2 Rear view ........................KCP coupler (optional) ....................Electronic Safety Circuit (ESC) safety logic ..............
Page 4 KR C2 edition05 Technical data ....................Basic data ........................KCP coupler (optional) ....................Dimensions of robot controller ..................Minimum clearances, robot controller ................Minimum clearances, top-mounted / technology cabinet ..........Swing range for cabinet door ..................Plates and labels ......................
Page 5 Contents 5.5.2 Power supply connection via CEE connector XS1 ............ EMERGENCY STOP circuit and safeguard ..............Interface X11 ........................PE equipotential bonding ....................Planning the KCP coupler option ..................Transportation ....................Transportation using lifting tackle ................... Transportation by pallet truck ..................Transportation by fork lift truck ..................
Page 6 10.18 Exchanging the KPS-27 ....................10.19 Exchanging the KSD ....................... 10.20 Removal and installation of the KCP coupler ..............10.21 Installing the KUKA System Software (KSS) ..............Troubleshooting ....................11.1 Repair and procurement of spare parts ................11.2 PC fault profiles ......................
Page 7 11.13.12 Selecting the properties of the ESC node ..............11.13.13 Assigning ESC nodes to a controller ................. 11.13.14 Error messages and troubleshooting ................. Appendix ......................KUKA Service ....................13.1 Requesting support ......................13.2 KUKA Customer Support ....................Index ........................V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en 7 / 157...
Page 8 KR C2 edition05 8 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 9: Introduction
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 pro- gram can be found at www.kuka.com or can be obtained directly from our subsidiaries.
Page 10 KR C2 edition05 Term Description Teach pendant (KUKA Control Panel) KUKA Robot Language KUKA System Software MFC3 Multi-function card Resolver Digital Converter RoboTeam A number of robots whose continuous path motions are synchronized, or both synchronized and geometrically coordinated SafeRobot...
Page 11: Product Description
Robot controller Connecting cables Teach pendant (KCP) Overview of the robot controller The robot controller is used for controlling the following systems: KUKA robots External kinematic system The robot controller consists of the following components: Control PC Power unit KCP teach pendant...
Page 12: Description Of The Control Pc
KR C2 edition05 Fig. 2-2: Overview of the robot controller Power unit Connection panel Control PC Mounting plate for customer components Safety logic (ESC) Description of the control PC With its fitted components, the PC performs all the functions of the robot con- Functions troller.
Page 13: Pc Interfaces
2. Product description Fig. 2-3: Overview of the control PC 1 PC 4 Drives (optional) 2 PC interfaces 5 Batteries 3 PC fan 2.3.1 PC interfaces Overview Fig. 2-4: Control PC interfaces Item Interface Item Interface PCI slots 1 to 6 X961 power supply DC (>>>...
Page 14: Pc Slot Assignment
KR C2 edition05 Item Interface Item Interface USB (2x) ST5 serial real-time inter- face COM 3 X804 Ethernet ST6 ESC/KCP etc. COM 1 serial interface ST3 drive bus to KPS600 LPT1 parallel interface ST4 serial RDC interface COM 2 serial interface...
Page 15: Motherboard
KVGA card DSE-IBS-C33 AUX card (optional) MFC3 card Network card (optional) LPDN scanner card (optional) Profibus master/slave card (optional) LIBO-2PCI card (optional) KUKA modem card (optional) free 2.3.3 Motherboard The following components are located on the motherboard: Configuration Processor Main memory (RAM)
Page 16: Hard Drive
The KUKA Robot Group has assembled, tested and supplied the mother- board with an optimum configuration. No liability will be accepted for modifi- cations to the configuration that have not been carried out by the KUKA Robot Group. 2.3.4 Hard drive The hard drive is partitioned into 2 "logical"...
Page 17 The MFC3 Standard card can accommodate a maximum of 2 DSE-IBS- C33 modules. Interface to the CI3 safety logic Fan monitoring Further information about the DeviceNet interface can be found in the corre- sponding KUKA documentation. V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en 17 / 157...
Page 18: Digital Servo-Electronics (Dse-Ibs-C33)
KR C2 edition05 The MFC3 Tech card contains the system I/Os and has the following func- MFC3 Tech tions: All functions of the MFC3 Standard card Interface for the CR option (RoboTeam) The MFC3 Tech card can only be used together with a CI3 Tech card.
Page 19: Batteries
They are backed up by the KPS600. Fig. 2-9: Batteries Description of the KUKA Control Panel (KCP) The KCP (KUKA Control Panel) is the teach pendant for the robot system. The Function KCP has all the functions required for operating and programming the robot system.
Page 20: Front View
KR C2 edition05 2.4.1 Front view Overview Fig. 2-10: Front view of KCP Mode selector switch Numeric keypad Drives ON Softkeys Drives OFF / SSB GUI Start backwards key EMERGENCY STOP button Start key Space Mouse STOP key Right-hand status keys...
Page 21: Rear View
2. Product description 2.4.2 Rear view Overview Fig. 2-11: Rear view of KCP Rating plate Enabling switch Start key Enabling switch Enabling switch Description Element Description KCP rating plate Rating plate The Start key is used to start a program. Start key The enabling switch has 3 positions: Not pressed...
Page 22 KR C2 edition05 Overview Fig. 2-12: KCP coupler LEDs and request button Fault LED (red), KCP coupler Request button with request LED (green) Fig. 2-13: KCP coupler card Connections Connect Item Description Request button LED connection ESC to the KCP...
Page 23: Electronic Safety Circuit (Esc) Safety Logic
2. Product description Electronic Safety Circuit (ESC) safety logic The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer- Overview aided safety system. It permanently monitors all connected safety-relevant components. In the event of a fault or interruption in the safety circuit, the pow- er supply to the drives is shut off, thus bringing the robot system to a standstill.
Page 24: Esc Nodes
KR C2 edition05 Enabling switches The node receives single-channel signals from: Drives ON AUTO mode, TEST mode If no KCP coupler is used, the ESC circuit will only function with the KCP con- nected. If the KCP is unplugged during operation without a KCP coupler, the drives are immediately switched off.
Page 25: Overview Of Ci3 Boards
2. Product description Signal Meaning Description name Enabling Input for external enabling switch (dual-chan- switches on the nel, 1-step). If the signal is interrupted in Test mode, the drives contactor drops out immedi- ately. Enabling switches, panic position Operating mode Inputs for external mode selector switch (sin- (A=Automatic, gle-channel).
Page 26: Ci3 Standard Board
KR C2 edition05 Board Own node Description CI3 Standard Indicates the following states: (>>> 2.6.3 "CI3 Standard Local E-STOP board" page 26) CI3 Extended Indicates the following states: (>>> 2.6.4 "CI3 Extend- Operating modes ed board" page 28) Local E-STOP...
Page 27 2. Product description Fig. 2-16: CI3 Standard board connections and relays Connections Item Designation Description Interface to MFC3 (CR safety signals) (optional) KPS connection MFC connection Interface to the RoboTeam lamp (optional). RDC power supply Connection of external mode selector switches (optional) CAN connection, I/O board Internal/external power supply and ESC cir-...
Page 28: Ci3 Extended Board
KR C2 edition05 Reset Item Designation Description ESC Reset button 2.6.4 CI3 Extended board This board has its own node and is used to indicate the following states of the Description ESC circuit: Operating modes Drives ON Local E-STOP The ESC circuit can be reset using the reset button.
Page 29: Ci3 Bus Board
2. Product description Item Designation Description KCP power supply and KCP CAN Peripheral interface for inputs and outputs Internal 24 V power supply Connection: robot controller, internal fan Connection of external controllers, E-STOP button on control cabinet Internal interface Peripheral interface, outputs > 500 mA Relays Item Designation...
Page 30 KR C2 edition05 Fig. 2-18: CI3 Bus board connections Connections Item Designation Description Interface to MFC3 (CR safety signals) (optional) KPS connection MFC connection Interface to the RoboTeam lamp (optional). RDC power supply Connection of external mode selector switches (optional)
Page 31: Ci3 Tech Board
CI3 Tech board The CI3 Tech board has its own node and is needed for the following compo- Description nents: KUKA.RoboTeam (Shared Pendant) KUKA.SafeRobot SafetyBUS Gateway Output to the top-mounted cabinet (external axes) Power supply to a 2nd RDC via X19A...
Page 32: Description Of The Power Unit
(optional) Multi-power tap (OUT2) (optional) SafetyBUS Gateway interface (optional) X19A 2nd RDC RoboTeam/E7 KUKA Guiding Device (KGD) interface (optional) Peripheral interface, outputs > 500 mA Internal interface Connection of external controllers, E-STOP button on control cabinet Connection: robot controller, internal fan...
Page 33: Power Supply Unit Kps600
2. Product description Mains filter Fig. 2-20: Power unit Low-voltage power supply KPS-27 Fuse elements (24 V without battery back-up) Mains filter Main switch (EU version) Fan for inner cooling circuit Power supply unit KPS600 KSDs for 2 external axes (option) KSDs for 6 robot axes Fuse elements (24 V with battery back-up) 2.7.1...
Page 34 KR C2 edition05 Ballast resistor Control cabinet interior The following components are connected to the integrated 24 V power supply: 24 V supply Motor brakes Customer interface Control PC The KPS 600 supplies the energy to the intermediate circuit and includes:...
Page 35: Fuses
2. Product description Item Connector Description X-K1a Interface to the power board for the K1 auxiliary contacts (internal) Control connections K1 24 V from low-voltage power supply X123 User interface X110 Fan/resistor monitoring X114 Additional inputs to the control board X121 Interbus input X122...
Page 36: Low-Voltage Power Supply Kps-27
KR C2 edition05 Values Item Fuse Value in A Circuit KPS600 power supply KPS-27 power supply 0. 63 External fan power supply 24 V DC voltage from KPS-27 24 V DC voltage from KPS-27 Lighting 24 V DC (optional) CI3 power supply...
Page 37 2. Product description Interbus interface for the drive bus Monitoring of the motor current and short-circuit protection Heat sink temperature monitoring Communication monitoring Fig. 2-24: Servo drive module 2 sizes are used: Sizes Size 1 (BG 1) KSD-08/16/32 Size 2 (BG 2) KSD-48/64 The designations 08 to 64 give the max.
Page 38: Mains Filter
KR C2 edition05 The LEDs on the servo drive modules indicate the operating status and any faults that may be present. (>>> 11.9 "Error messages on the KSD" page 115) 2.7.5 Mains filter The task of the mains filter (suppressor filter) consists of:...
Page 39: Description Of Interfaces
2. Product description Fig. 2-27: Inner cooling circuit Heat sink of the KSD Inner heat exchanger Fan for inner cooling circuit Heat sink of the KPS Air duct The robot controller can optionally be equipped with an additional cooling unit. Optional cooling Description of interfaces The connection panel of the control cabinet consists as standard of connec-...
Page 40: Power Supply Connection
KR C2 edition05 Connection panel Fig. 2-28: KR C2 ed05 connection panel X1/XS1 power supply connec- Optional tion X20 motor connection X19 KCP connection X7 motor connection X21 RDC connection Optional PE1 ground conductor to the robot Optional PE2 main infeed ground con-...
Page 41 2. Product description Caution! If the robot controller is connected to a power system without a grounded neutral, this may cause malfunctions in the robot controller and material dam- age to the power supply units. The robot controller may only be operated with grounded-neutral power supply systems.
Page 42: Kcp Connector X19
KR C2 edition05 2.9.2 KCP connector X19 Connector pin allocation 42 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 43: Motor Connector X20, Axes 1 To 6
2. Product description 2.9.3 Motor connector X20, axes 1 to 6 Connector pin allocation V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en 43 / 157...
Page 44: Motor Connector X7 (Optional)
KR C2 edition05 2.9.4 Motor connector X7 (optional) Connector pin allocation 44 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 45: Data Cable X21, Axes 1 To 8
2. Product description 2.9.5 Data cable X21, axes 1 to 8 Connector pin allocation 2.10 Description of the mounting plate for customer components (optional) The mounting plate for customer components is a mounting plate on the inside Overview of the door which can be fitted as an option for integrating external customer equipment.
Page 46 KR C2 edition05 Fig. 2-30: Mounting plate for customer components Drives (optional) Mounting plate for customer components The drives project into the installation area of the mounting plate. Technical data Designation Values Weight of installed components max. 5 kg Power dissipation of installed components max.
Page 47: Technical Data
3. Technical data Technical data Basic data Basic data Control cabinet type KR C2 edition05 Number of axes max. 8 Weight approx. 185 kg Protection classification IP 54 Sound level according to DIN average: 67 dB (A) 45635-1 Installation with other cabinets...
Page 48: Kcp Coupler (Optional)
KR C2 edition05 Humidity class acc. to EN 60204/ 4.4.4 Altitude class according to DIN 40040 Vibration resistance During During continuous Type of loading transportation operation r.m.s. acceleration (sus- 0.37 g 0.1 g tained oscillation) Frequency range (sustained 4 - 120 Hz...
Page 49: Dimensions Of Robot Controller
3. Technical data Digital inputs 24 V DC pulsed, resistive load only Dimensions 147 mm x 73 mm Dimensions of robot controller Fig. 3-1: Dimensions (in mm) 1 Cooling unit (optional) 3 Side view 2 Front view 4 Top view Minimum clearances, robot controller Fig.
Page 50: Minimum Clearances, Top-Mounted / Technology Cabinet
KR C2 edition05 Minimum clearances, top-mounted / technology cabinet Fig. 3-3: Minimum clearances with top-mounted / technology cabinet Top-mounted cabinet Technology cabinet Swing range for cabinet door Swing range, standalone cabinet: Door with computer frame approx. 180° Swing range, butt-mounted cabinets: Door approx.
Page 51 3. Technical data Fig. 3-4: Plates and labels The plates may vary slightly from the examples illustrated depending on the specific cabinet type or as a result of updates. V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en 51 / 157...
Page 52 KR C2 edition05 Designations Plate no. Designation Hot surface warning sign Hand injury warning sign Discharging time warning KR C2 ed05 rating plate Reference to operating instructions PC rating plate Start-up warnings on the door Grounded neutral Check for tight fit of screws and terminals...
Page 53: Safety
4. Safety Safety System planning 4.1.1 EC declaration of conformity and declaration of incorporation The system integrator must issue a declaration of conformity for the overall EC declaration of system in accordance with Directive 98/37/EC (Machinery Directive). The dec- conformity laration of conformity forms the basis for the CE mark for the system.
Page 54: Workspace, Safety Zone And Danger Zone
KR C2 edition05 Further information is contained in the corresponding standards and regula- tions. Requirements on safety gates are: Safety gates The number of safety gates in the fencing must be kept to a minimum. All safety gates must be safeguarded by means of an operator safety sys- tem (interface X11).
Page 55: Description
4. Safety Robot Braking distance Braking distance Description 4.2.1 Category of the safety-oriented circuits The following circuits correspond to Category 3 in accordance with EN 954-1: EMERGENCY STOP systems Enabling switches Operator safety Operating modes Qualifying inputs 4.2.2 Stop reactions Stop reactions of the robot system are triggered in response to operator ac- tions or as a reaction to monitoring functions and error messages.
Page 56: Labeling On The Robot System
Identification plates 4.2.4 Safety information Safety information cannot be held against the KUKA Robot Group. Even if all safety instructions are followed, this is not a guarantee that the robot system will not cause personal injuries or material damage. No modifications may be carried out to the robot system without the authori- zation of the KUKA Robot Group.
Page 57: Safety Features
4. Safety Safety features 4.3.1 Overview of the safety features The following table indicates the operating modes in which the safety features are active. Safety features AUT EXT active active Operator safety active active Emergency Stop button (STOP 0) active active Emergency Stop button (STOP 1)
Page 58: Emergency Stop Button
KR C2 edition05 In the event of a loss of signal during Automatic operation (e.g. safety gate is opened), the drives are deactivated after 1 s and the robot stops with a STOP 1. Once the signal is active at the input again (e.g. safety gate closed and sig- nal acknowledged), Automatic operation can be resumed.
Page 59: Jog Mode
If the robot hits an obstruction or a buffer on the mechanical end stop or axis range limitation, this can result in material damage to the robot. The KUKA Robot Group must be consulted before the robot is put back into operation (>>>...
Page 60: Axis Range Monitoring (Option)
KR C2 edition05 This option can be retrofitted. Further information is contained in the working range limitation operating in- structions. 4.3.9 Axis range monitoring (option) Most robots can be fitted with dual-channel axis range monitoring systems in main axes A1 to A3. The safety zone for an axis can be adjusted and moni- tored using an axis range monitoring system.
Page 61: Kuka.saferobot (Option)
4. Safety 4.3.12 KUKA.SafeRobot (option) KUKA.SafeRobot is an option with software and hardware components. This option may only be retrofitted after consultation with the KUKA Robot Group. Connection to an external safety logic Properties Monitoring that can be activated using safe inputs...
Page 62: Safety Measures
KR C2 edition05 The tasks can be distributed as shown in the following table. Example Maintenance Tasks Operator Programmer technician Switch robot controller on/off Start program Select program Select operating mode Calibration (tool, base) Master the robot Configuration Programming Start-up...
Page 63: Transportation
4. Safety Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. Indicate the fault by means of a label with a corresponding warning. Keep a record of the faults. Eliminate the fault and carry out a function test.
Page 64: Programming
KR C2 edition05 4.5.4 Programming The following safety measures must be carried out during programming: It must be ensured that no persons are present within the danger zone of the robot during programming. New or modified programs must always be tested first in operating mode If the drives are not required, they must be switched off to prevent the robot from being moved unintentionally.
Page 65: Planning
5. Planning Planning Overview of planning This is an overview of the most important planning specifications. The pre- cise planning depends on the application, the robot type, the technology packages used and other customer-specific circumstances. For this reason, the overview does not claim to be comprehensive. Robot controller Step Description...
Page 66: Installation Conditions
KR C2 edition05 Installation conditions Dimensions Fig. 5-1: Dimensions (in mm) 1 Cooling unit (optional) 3 Side view 2 Front view 4 Top view Minimum clearances Fig. 5-2: Minimum clearances (dimensions in mm) 66 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 67: Connection Conditions
5. Planning Minimum clear- ances with top- mounted cabinet Fig. 5-3: Minimum clearances with top-mounted / technology cabinet Top-mounted cabinet Technology cabinet Swing range for door Swing range, standalone cabinet: Door with computer frame approx. 180° Swing range, butt-mounted cabinets: Door approx.
Page 68: Power Supply Connection
KR C2 edition05 Rated power input 7.3 kVA, see rating plate Standard Rated power input 13.5 kVA, see rating plate Heavy-duty robot Palletizer Press-to-press robot Mains-side fusing min. 3x25 A slow-blowing, max. 3x32 A slow-blowing, see rating plate RCCB trip current difference...
Page 69: Power Supply Connection Via X1 Harting Connector
5. Planning Overview Fig. 5-4: Power supply connection * The N-conductor is only necessary for the service socket option with a 400 V power supply. The robot controller must only be connected to a power system with a clock- wise rotating field. Only then is the correct direction of rotation of the fan mo- tors ensured.
Page 70: Emergency Stop Circuit And Safeguard
KR C2 edition05 Fig. 5-6: Power supply connection XS1 EMERGENCY STOP circuit and safeguard The following examples show how the EMERGENCY STOP circuit and safe- guard of the robot system can be connected to the periphery. Example Fig. 5-7: Robot with periphery 70 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 71: Interface X11
5. Planning Example Fig. 5-8: Robot with periphery and external power supply Interface X11 EMERGENCY STOP devices must be connected via interface X11 or linked Description together by means of higher-level controllers (e.g. PLC). Take the following points into consideration when wiring interface X11: Wiring System concept Safety concept...
Page 72 KR C2 edition05 Connector pin allocation 72 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 73 5. Planning Signal Description Comments +24 V internal ESC power supply max. 2 A 0 V internal 24 V external In the absence of an external An external power supply is power supply, 24 V / 0 V must recommended for interlinked 0 V external be jumpered internally.
Page 74: Pe Equipotential Bonding
KR C2 edition05 Signal Description Comments Drives ON chan- 11 / 12 Floating contacts (max. 2 A) Is closed if the “Drives ON” nel A signal “Drives ON”. contactor is energized. These contacts are only availa- ble if a CI3 Extended or CI3 Tech board is used.
Page 75: Planning The Kcp Coupler Option
5. Planning 1 Equipotential bonding to KR C2 4 Cable duct ed05 2 Equipotential bonding from the 5 Equipotential bonding from the connection panel to the cable cable duct to the robot duct 3 Connection panel, KR C2 ed05 6 Equipotential bonding connec- tion on the robot Fig.
Page 76 KR C2 edition05 76 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 77: Transportation
6. Transportation Transportation Transportation using lifting tackle The control cabinet must be switched off. Preconditions No cables may be connected to the control cabinet. The door of the control cabinet must be closed. The control cabinet must be upright. The anti-toppling bracket must be fastened to the control cabinet. Lifting tackle with or without lifting frame Necessary equipment...
Page 78: Transportation By Pallet Truck
KR C2 edition05 Transportation by pallet truck The control cabinet must be switched off. Preconditions No cables may be connected to the control cabinet. The door of the control cabinet must be closed. The control cabinet must be upright. The anti-toppling bracket must be fastened to the control cabinet.
Page 79: Start-Up
7. Start-up Start-up Start-up overview This is an overview of the most important steps during start-up. The precise sequence depends on the application, the robot type, the technology pack- ages used and other customer-specific circumstances. This overview refers to the start-up of the robot system. The start-up of the overall system is not within the scope of this documentation.
Page 80: Installing The Robot Controller
KR C2 edition05 Software Step Description Information Check machine data. Detailed information is contained in the operating and programming Master the robot without a load. instructions. Mount the tool and master the robot with a load. Check the software limit switches and adapt them if required.
Page 81: Connecting The Kcp
7. Start-up Control cable to the robot The following cables may be provided for additional applications: Motor cable for external axes Peripheral cables Danger! The robot controller is preconfigured for specific robots. If cables are inter- changed, the robot may receive incorrect data and can thus cause personal injury or material damage.
Page 82: Reversing The Battery Discharge Protection Measures
KR C2 edition05 Reversing the battery discharge protection measures To prevent the batteries from discharging before the controller has been start- Description ed up for the first time, the robot controller is supplied with connector X7 dis- connected from the KPS600.
Page 83: Checking The Direction Of Rotation Of The External Fan
3. Switch on the main switch. The control PC begins to run up the operating system and the control software. Information about operator control of the robot using the KCP can be found in the operating and programming instructions for the KUKA System Soft- ware (KSS). 7.11 Checking the direction of rotation of the external fan Check outlet (2) on the rear of the robot controller.
Page 84 KR C2 edition05 84 / 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en...
Page 85: Operation
8. Operation Operation Display and operator control elements of the KCP coupler (optional) Overview Fig. 8-1: KCP coupler LEDs and request button Fault LED (red), KCP coupler Request button with request LED (green) 8.1.1 Uncoupling the KCP 1. Press the request button for at least 1 s. Procedure The green request LED flashes.
Page 86: Booting The Robot Controller From A Usb Stick
KR C2 edition05 1. Set the operating mode on the KCP to the same operating mode as on the Procedure robot controller (the operating mode display is application-specific (>>> 5.9 "Planning the KCP coupler option" page 75)). If the KCP is connected with the wrong operating mode selected, the robot controller switches to the operating mode set on the KCP.
Page 87: Maintenance
9. Maintenance Maintenance Maintenance table Fig. 9-1: Maintenance points Maintenance table Item Activity Time re- Maintenance interval quired [min] Clean fan for inner Depends on installation cooling circuit with conditions and degree of brush. fouling; however, no later than every 2 years Clean fan for outer cooling circuit with brush.
Page 88: Cleaning The Robot Controller
KR C2 edition05 Item Activity Time re- Maintenance interval quired [min] Exchange the bat- 2 years teries. (>>> 10.10 "Excha nging the batteries" page 95) Exchange the 5 years motherboard bat- tery. (>>> 10.7 "Exchan ging the mother- board battery"...
Page 89: Repair
10. Repair Repair 10.1 Service jumper plug X11 The service jumper plug X11 is a Harting connector with a male insert, type Han 108DD, housing size 24B. Connector pin allocation Caution! The jumper plug is only to be used during start-up and troubleshooting. If the jumper plug is used, the connected safety components are disabled.
Page 90: Exchanging The Internal Fan
KR C2 edition05 10.2 Exchanging the internal fan The robot controller must be switched off and secured to prevent unau- Preconditions thorized persons from switching it on again. Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines.
Page 91: Exchanging The External Fan
10. Repair 10.3 Exchanging the external fan The robot controller must be switched off and secured to prevent unau- Preconditions thorized persons from switching it on again. Back-up must be completed. The power cable must be de-energized. Observe the ESD guidelines. 1.
Page 92: Exchanging The Pc
KR C2 edition05 Observe the ESD guidelines. 1. Open the control cabinet door. Procedure 2. Remove the foam ring. 3. Exchange the filter insert. 4. Insert the foam ring so that it is flush with the pressure relief plug. Fig. 10-3: Exchanging the pressure relief plug...
Page 93: Exchanging The Pc Fans
10. Repair Fig. 10-4: Removing and installing the control PC Plug-in connections on the PC Transport safeguard screw Knurled nut 10.6 Exchanging the PC fans The robot controller must be switched off and secured to prevent unau- Preconditions thorized persons from switching it on again. Back-up must be completed.
Page 94: Exchanging The Motherboard Battery
Cable strap 10.7 Exchanging the motherboard battery The battery on the motherboard of the control PC may only be exchanged by authorized maintenance personnel in consultation with the KUKA customer support service. 10.8 Exchanging the motherboard A defective motherboard is not exchanged separately, but together with the 10.9...
Page 95: Exchanging The Batteries
10. Repair Fig. 10-6: Exchanging DIMM memory modules Side tabs DIMM memory module socket Asymmetrically positioned re- cesses 10.10 Exchanging the batteries The robot controller must be switched off and secured to prevent unau- Preconditions thorized persons from switching it on again. Back-up must be completed.
Page 96: Removal And Installation Of The Cd-Rom Drive (Optional)
KR C2 edition05 Fig. 10-7: Connection example: Batteries Spring clamp In case of long-term storage, the batteries must be charged every 6 months to Storage instruction avoid the risk of damage due to self-discharge. 10.11 Removal and installation of the CD-ROM drive (optional)
Page 97: Removal And Installation Of The Floppy Disk Drive (Optional)
10. Repair Fig. 10-8: Exchanging the CD-ROM drive Fastening screw of the drives Fastening screws of the CD- holder ROM drive 10.12 Removal and installation of the floppy disk drive (optional) The robot controller must be switched off and secured to prevent unau- Preconditions thorized persons from switching it on again.
Page 98: Exchanging The Hard Drive
7. Place the hard drive on the holder and fasten it with the retaining clip. 8. Close the PC housing and the control cabinet door. 9. Install the operating system and the KUKA System Software (KSS). Fig. 10-10: Exchanging the hard drive...
Page 99: Kvga Card Settings
10. Repair 3. Unplug the connections to the KVGA card. 4. Release the fastenings of the card and pull the card out of the slot. 5. Check the new card for mechanical damage, insert it into the slot and tight- en the fastening screws.
Page 100: Exchanging The Kps600
KR C2 edition05 5. Unscrew the DSE-IBS-C33 from the MFC3 and unplug it. 6. Plug on the new DSE-IBS-C33 and screw it down. 7. Plug the MFC3 into its slot and tighten the fastening screws. 8. Plug in the connections to the card.
Page 101: Exchanging The Ksd
10. Repair Wait 5 minutes until the intermediate circuit has discharged. Caution! Voltages in excess of 50 V (up to 600 V) can be present in the KPS, the KSDs and the intermediate-circuit connecting cables up to 5 minutes after the control cabinet has been switched off! 1.
Page 102: Removal And Installation Of The Kcp Coupler
3. Remove the fastening screws (1). 4. Install and fasten the new KCP coupler card. 5. Plug in all connectors. 10.21 Installing the KUKA System Software (KSS) Further information is contained in the operating and programming instruc- tions for the KUKA System Software (KSS).
Page 103: Troubleshooting
Troubleshooting 11.1 Repair and procurement of spare parts Repairs to the robot controller may only be carried out by KUKA customer sup- Repairs port personnel or by customers who have taken part in a relevant course of training held by the KUKA Robot Group.
Page 104 Remove PC card and run con- bus) troller up again. Exchange PC card Motherboard defective Exchange the PC KUKA.HMI does not boot, and Defective files in the software Reinstall control software is aborted with a General Pro- installation tection fault...
Page 105: Mfc3 Error Messages
11. Troubleshooting 11.3 MFC3 error messages Effects Causes Remedy Controller hangs when loading MFC cannot be initialized Remove PC cards and run the software components PC up again MFC3 incorrectly connected Check MFC3 slot PC card (e.g. Interbus) interfer- Exchange the MFC3 ing with functioning of MFC3 PCI bus on motherboard faulty Exchange motherboard...
Page 106: Field Bus Communication Error Messages
KR C2 edition05 11.5 Field bus communication error messages Effects Causes Remedy Communication via diagnostic Data cable, periphery faulty Check data cable, periphery interface not possible Diagnostic interface on field Exchange field bus card bus card defective Error message "xxxxx I/O...
Page 107 11. Troubleshooting Fuses Item Designation Value in A Description 24 V DC fan monitoring 24 V DC interface VCC 24 V DC interface VCC 24 V DC interface VCC 24 V DC VCC-ESC RDC supply LEDs Item Designation Description LED16 (red) Fuse monitoring for F2 LED5 (red) Fuse monitoring for F16...
Page 108: Ci3 Extended Board
KR C2 edition05 11.6.2 CI3 Extended board Overview Fig. 11-2: CI3 Extended board fuses and LEDs Fuses Item Designation Value in A Description 24 V DC fan monitoring 24 V DC interface VCC 24 V DC interface VCC 24 V DC interface VCC...
Page 109: Ci3 Bus Board
11. Troubleshooting Item Designation Description LED12 (red) Fuse monitoring for F23 LED18 (red) ESC bus KCP error LED17 (green) ESC bus KCP OK LED27 (red) ESC bus MFC error LED28 (green) ESC bus MFC OK LED22 (red) ESC bus, local ESC node error LED21 (green) ESC bus, local ESC node OK LED19 (red)
Page 110: Ci3 Tech Board
KR C2 edition05 LEDs Item Designation Description LED16 (red) Fuse monitoring for F2 LED5 (red) Fuse monitoring for F16 LED4 (red) Fuse monitoring for F12 LED2 (red) Fuse monitoring for F13 LED6 (red) Fuse monitoring for F1 LED7 (red) Fuse monitoring for F14...
Page 111 11. Troubleshooting Item Designation Value in A Description 24 V DC drives ON 24 V DC drives ON 24 V DC drives ON 24 V DC VCC-ESC 24 V DC lamp CR RDC supply MPI supply LEDs Item Designation Description LED16 (red) Fuse monitoring for F2 LED5 (red)
Page 112: Kps 600 Fuses, Messages And Error Displays
KR C2 edition05 11.7 KPS 600 fuses, messages and error displays Overview Fig. 11-5: KPS 600 LED display and fuses LED 1 (red) Fuse F5 LED 2 (green) Fuse F1 LED 3 (red) Fuse F3 LED 4 (red) Fuse F4...
Page 113 11. Troubleshooting LEDs 1 and 2 LED 1 LED 2 Priority Meaning Processor without power supply Flashes at Intermediate circuit voltage 1.5 Hz below 60 V Intermediate circuit voltage above 60 V Flashes at Communication error 6 Hz Flashes at Brake error 3 Hz Main contactor K1 stuck...
Page 114 KR C2 edition05 Display in message Meaning / cause Remedy window Parameter error PMx Checksum error in Restart checksum parameter set 1 Exchange KPS Parameter error PMx Checksum error in the Restart control control unit device set Exchange KPS Drives error PMx no.:...
Page 115: Error Messages
11. Troubleshooting Display in message Meaning / cause Remedy window Brake error Ax/PMx Brake error, main axes Brakes not con- channel x nected Short circuit on brake cable Brake error Ax/PMx Brake error, external Brakes not con- channel x axes nected Short circuit on brake cable...
Page 116 KR C2 edition05 Fig. 11-7: KSD error display LED 1 (red) LED 2 (green) LED 1 LED 2 Meaning No 24 V Undefined state Flashes quickly Flashes quickly Fault is present > U limit Flashes slowly Flashes slowly Message is present (except in case <...
Page 117: Kcp Coupler Led Display (Optional)
11. Troubleshooting Display in message Meaning / cause Remedy window HEAT SINK Heat sink overtemperature Check control cabinet TEMPERA- fans / cooling circuit TURE Ax Reduce load on axis (re- duce OVR, $VEL_AXIS or $ACC_AXIS) Parameter Checksum error in parame- Check the KSD error Ax ter set 1...
Page 118 KR C2 edition05 Fig. 11-8: KCP coupler LEDs and request button LED 1 (red) Item State Meaning Internal error in KCP coupler. No error Flashes slowly Internal ESC communications error (approx. 1 Hz) Flashes quickly ESC protocol timeout from KCP (approx.
Page 119: Kcp Coupler Troubleshooting
11. Troubleshooting KCP coupler card Fig. 11-9: LEDs on the KCP coupler card Item State Meaning 24 V ESC Switched 24 V ESC Test output channel B Test output channel A Switched 24 V KCP 24 V KCP 5 V KCP coupler 11.11 KCP coupler troubleshooting Fault Remedy...
Page 120: Dse-Rdw Diagnosis
KR C2 edition05 11.12 DSE-RDW diagnosis The DSE-RDW diagnostic tool indicates the current state of communication Overview between the DSE and the RDC, on the one hand, and the DSE and the drive bus, on the other. 11.12.1 Description of the user interface Select the menu sequence Setup >...
Page 121: Setting The Language
11. Troubleshooting Parameter Description 2.DSE There is no second DSE present in this case. The 4 display boxes are the same as for the first DSE. Status line: Version number of the DSE-RDW diag- nostic tool Type of control cabinet Current value of the DSE interrupt coun- ter: incrementation of the counter indi- cates that the DSE control program is...
Page 122: Dse Ibs Information
KR C2 edition05 Fig. 11-11: MFC register display Parameter Description Version of the MFC module used Address section RTACC Internal data Address sesction 82C54 Timer Revision number Reserved area Binary Input Input ESC0 Input ESC1 State register ESC diagnosis interface...
Page 123: Rdc Table
11. Troubleshooting Fig. 11-12: DSE IBS information Parameter Description Control type Type of controller (KR C2ed05, KR C3) DSE hardware Hardware version of the DSE DSE Clock Speed Clock frequency of the DSE used CPLD version Internal version numbers SW functionality SW version DPRAM version DPRAM revision...
Page 124: Rdc Offset And Symmetry Adjustment
KR C2 edition05 Fig. 11-13: RDC table Softkeys Softkey Description PgDn Moves down one line in the table PgUp Moves up one line in the table Export Saves the current data to the hard drive Refresh Starts / stops continuous updating of the display Start cont.
Page 125: Check Rdc-Dse Communication
11. Troubleshooting Fig. 11-14: RDC offset and symmetry Parameter Description 1.RDC2 offset und symme- Displays all adjustment data for the axes Softkeys Softkey Description Set default values The default values should be set after: Exchanging motors Exchanging the RDC module Sporadic encoder errors 11.12.7 Check RDC-DSE communication Under "System info", select 1.RDC2 >...
Page 126 KR C2 edition05 Fig. 11-15: Check communication Parameter Description System info - Check com- The RDC sends data words to the DSE in a munication 125 µs cycle. This function is used to check the communication between the DSE and...
Page 127: Drive Bus Diagnostics
11. Troubleshooting Softkey Description Refresh Updates the display Start cont. display Starts / stops continuous updating of the display 11.12.8 Drive bus diagnostics Under "System info", select 1.Drive Bus > Diagnostics. Procedure The following parameters are displayed: Description Fig. 11-17: Drive bus diagnostics Parameter Description Number of cycles...
Page 128: Drive Bus Error List
KR C2 edition05 11.12.9 Drive bus error list Under "System info", select 1.Drive Bus > Error list. Procedure The error statistics are displayed with the drive bus running. Description Fig. 11-18: Drive bus error list Softkeys Softkey Description Start cont. display...
Page 129 11. Troubleshooting Description Fig. 11-19: Drive bus - KPS Parameter Description Lecom error Lenze communication error number Hardware version Control and power units Intermediate voltage Voltages, currents and temperatures of the Low voltage supply Accu voltage Accu current Ballast temperature Heat sink temperature Housing temperature Operating time counter...
Page 130: Drive Bus - Ksd-16
KR C2 edition05 11.12.11Drive bus - KSD-16 Under "System info", select 1.Drive Bus > 02-KSD-16. Procedure The following parameters are displayed: Description Fig. 11-20: Drive bus - KSD Parameter Description Lecom error Lenze communication error number Hardware version Control and power units...
Page 131: Kps600 Error Messages
11. Troubleshooting Softkeys Softkey Description Start cont. display Starts / stops continuous updating of the display Refresh Updates the display Export Code Table Saves the current code table to the hard drive (example: C:\KRC\Roboter\Log\Drivebus1-4_KSD1- 8.log) 11.12.12KPS600 error messages Lecom trip Message error Description...
Page 132: Ksd Error Messages
KR C2 edition05 11.12.13KSD error messages Valid from Firmware V0.3 onwards Lecom trip Message error Description text number "ok" Device state OK "Pr1-Trip" Checksum error in parameter set 1 "HO5-Trip" Checksum error in the control unit device set "CCr-Trip" Microcontroller crash "OC1-Trip"...
Page 133: Log File
11. Troubleshooting Fig. 11-21: Example: a controller with three ESC nodes Item Description Display of all the connected controllers. The controller currently selected is highlighted. Display of all the nodes present in the safety circuit. The acti- vated node is highlighted. Display of the signal statuses or the accumulated errors and the location of the source of the errors.
Page 134: State Display Of The Esc Nodes
KR C2 edition05 11.13.5 State display of the ESC nodes The states of an individual node and its values can be viewed in the state dis- Description play. The values are updated cyclically. The state of the ESC node is shown in color.
Page 135: Error Display Of The Esc Nodes
11. Troubleshooting Color State Element Help text Gray False E-STOP output Green True Gray False Local E-STOP Green True Gray False AAUTO AUTO output Green True Gray False ATEST TEST output Green True Gray False Res1 (Reserved signal) Green True Green False RAE2...
Page 136: Displaying All Status Bits
KR C2 edition05 Error Error in node CCC_Error Node XX Initialization error Node XX Configuration error Node XX Hardware error Node XX Communication error Node XX Software error Node XX IO monitoring error Node XX Error protocol received Node XX...
Page 137: Configuring Controllers
11. Troubleshooting Fig. 11-24: State of the status bits in the ESC circuit 11.13.8 Configuring controllers A controller must be highlighted. Preconditions Switch to Expert level. Open menu by pressing the Configure softkey. Procedure All the nodes present in the ESC circuit are determined when the ESC diag- Description nosis is started.
Page 138: Configuring The Controller Properties
KR C2 edition05 Fig. 11-25: Controller configuration menu The KUKA default settings are overwritten. Softkey Softkey Description Next Window The first node is highlighted. Insert Rob. A controller is added. Delete Rob. The selected controller is removed. Move left The selected controller is moved to the left.
Page 139: Configuring Esc Nodes
11. Troubleshooting Fig. 11-26: Example: robot property boxes Parameter Description Name Name of the controller Shortcut Short designation of the controller Icon Controller icon Config name Name of the current configuration set The contents of the Config name box are valid for all controllers. It is only necessary to enter the configuration name once.
Page 140: Selecting The Display For Signals
KR C2 edition05 Description Fig. 11-27: Configuring ESC nodes Softkey Softkey Description Next Window The first node is highlighted. Show signals / Property Toggles between configuring the properties and configuring the signals. Drag / Drop Assigns ESC nodes to a controller.
Page 141: Selecting The Properties Of The Esc Node
11. Troubleshooting Fig. 11-28: Example: signals of a KCP ESC node 11.13.12Selecting the properties of the ESC node Display the property boxes for by pressing the Property softkey. Procedure The property boxes of the selected ESC node are displayed and the softkey changes to Show signals.
Page 142: Assigning Esc Nodes To A Controller
KR C2 edition05 Fig. 11-29: Example: KPS property boxes Parameter Description Name Name of the node Shortcut Short designation of the node Icon Node icon Config name Name of the current configuration set 11.13.13Assigning ESC nodes to a controller The softkeys can be used to assign an ESC node to a specific controller.
Page 143 11. Troubleshooting Message text Cause Troubleshooting Invalid header byte Defective KCP or KPS, defec- Exchange the defective mod- tive CI3 board, defective con- ule, carry out a visual inspec- nectors or connecting cables, tion of the bus wiring. voltage dips. Interface error Defective KCP or KPS, defec- Exchange the defective mod-...
Page 144 KR C2 edition05 Message text Cause Troubleshooting Crossed connection error on: Short-circuit TA24(A) / Check wiring of the input for External E-STOP TA24(B). Single-channel wir- external E-Stop (ENA). ing. Channels A-B inter- changed. Crossed connection error on: Short-circuit TA24(A) /...
Page 145: Appendix
12. Appendix Appendix Name Definition Edition Low Voltage Directive: 1993 73/23/EEC Council Directive of 19 February 1973 on the harmonization of the laws of Member States relating to electrical equipment designed for use within certain voltage limits EMC Directive: 1993 89/336/EEC Council Directive of 3 May 1989 on the approximation of the laws of the Member...
Page 146 KR C2 edition05 Name Definition Edition Electromagnetic compatibility (EMC): 2002 EN 61000-4-4 Part 4-4: Testing and measurement tech- niques - Electrical fast transient/burst immunity test Electromagnetic compatibility (EMC): 2001 EN 61000-4-5 Part 4-5: Testing and measurement tech- niques; Surge immunity test...
Page 147: Kuka Service
For further assistance, please con- tact your local KUKA subsidiary. Faults leading to production downtime are to be reported to the local KUKA subsidiary within one hour of their occurrence. The following information is required for processing a support request:...
Page 148 Chile Santiago de Chile Chile Tel. +56 2 331-5951 Fax +56 2 331-5952 robotec@robotec.cl www.robotec.cl KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd. China Shanghai Qingpu Industrial Zone No. 502 Tianying Rd. 201712 Shanghai P.R. China Tel. +86 21 5922-8652 Fax +86 21 5922-8538 Franz.Poeckl@kuka-sha.com.cn...
Page 149 13. KUKA Service KUKA Automatisme + Robotique SAS France Techvallée 6 Avenue du Parc 91140 Villebon s/Yvette France Tel. +33 1 6931-6600 Fax +33 1 6931-6601 commercial@kuka.fr www.kuka.fr KUKA Roboter GmbH Germany Blücherstr. 144 86165 Augsburg Germany Tel. +49 821 797-4000 Fax +49 821 797-1616 info@kuka-roboter.de...
Page 150 47100 Puchong Selangor Malaysia Tel. +60 3 8061-0613 or -0614 Fax +60 3 8061-7386 info@kuka.com.my KUKA de Mexico S. de R.L. de C.V. Mexico Rio San Joaquin #339, Local 5 Colonia Pensil Sur C.P. 11490 Mexico D.F. Mexico Tel. +52 55 5203-8407 Fax +52 55 5203-8148 info@kuka.com.mx...
Page 151 North End 6000 Port Elizabeth South Africa Tel. +27 41 391 4700 Fax +27 41 373 3869 www.jendamark.co.za KUKA Sistemas de Automatización S.A. Spain Pol. Industrial Torrent de la Pastera Carrer del Bages s/n 08800 Vilanova i la Geltrú (Barcelona) Spain Tel.
Page 152 KR C2 edition05 KUKA Robot Automation Taiwan Co. Ltd. Taiwan 136, Section 2, Huanjung E. Road Jungli City, Taoyuan Taiwan 320 Tel. +886 3 4371902 Fax +886 3 2830023 info@kuka.com.tw www.kuka.com.tw KUKA Robot Automation (M)SdnBhd Thailand Thailand Office c/o Maccall System Co. Ltd.
Page 153: Index
Index Index CI3 Tech board relays 32 Numbers 2nd RDC 31 Circuits, safety-oriented 55 73/23/EEC 53, 145 COM 1, serial interface 14 89/336/EEC 53, 145 COM 2, serial interface 14 97/23/EC 145 Connecting cables 11 98/37/EC 53, 145 Connecting cables, connecting 80 Connecting the KCP 81 Connecting the power supply 81 Connection conditions 67...
Page 154 Ethernet 14 KSD sizes 37 Exchanging the hard drive 98 KSD, exchange 101 Exchanging the KVGA card 98 KSD, KUKA Servo Drive 36 External E-STOP 24 KUKA Control Panel 19, 48 External EMERGENCY STOP 23, 57 KUKA Customer Support 147...
Page 155 PC fault profiles 103 Serial real-time interface 14 PC interfaces 13, 15 Service jumper plug X11 89 PC slot assignment 14 Service, KUKA Roboter 147 PC, exchange 92 Servo drive modules, KSD 32 PE equipotential bonding 74 Setting 63 PE equipotential bonding, connecting 81...
Page 156 KR C2 edition05 Support request 147 Swing range for cabinet door 50 Switching on the robot controller 82 System integrator 53, 61 Target group 9 Teach pendant 11 Technical data 47 Technical data, KCP coupler 48 Temperature monitoring 33 Test output 24...
Page 157 V3.3 11.07.2007 KRC-AD-KRC2ed05-BA en 157 / 157...

Kuka KR C2 edition05 Operating Instructions Manual

1 Introduction

2 Product Description

3 Technical Data

4 Safety

5 Planning

6 Transportation

7 Start-Up

8 Operation

9 Maintenance

10 Repair

11 Troubleshooting

12 Appendix

13 KUKA Service

Index

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Kuka KR C2 edition05

Table of Contents