BA KR C4 Compact En-2

Controller
KR C4 compact
Operating instructions
Issued: 11.09.2020
BA KR C4 compact V14
KUKA Deutschland GmbH
KR C4 compact
© Copyright 2020
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 KR C4 compact (PDF) en

PB2720
Book structure: BA KR C4 compact V12.2

BS3793
Version: BA KR C4 compact V14
2/198 | www.kuka.com BA KR C4 compact V14 | Issued: 11.09.2020

KR C4 compact
Contents
1 Introduction.............................................................................................. 9
1.1 Target group.......................................................................................................... 9
1.2 Industrial robot documentation.............................................................................. 9
1.3 Representation of warnings and notes................................................................. 9
1.4 Trademarks............................................................................................................ 10
1.5 Terms used............................................................................................................ 10
2 Product description................................................................................. 13
2.1 Description of the industrial robot......................................................................... 13
2.2 Overview of the robot controller........................................................................... 13
2.3 Control box............................................................................................................ 14
2.3.1 Control PC............................................................................................................. 15
2.3.2 Cabinet Control Unit, Small Robot....................................................................... 15
2.3.3 Low-voltage power supply unit............................................................................. 16
2.3.4 Batteries................................................................................................................. 16
2.3.5 Mains filter............................................................................................................. 16
2.4 Drive box (Drive Configuration (DC))................................................................... 16
2.5 Description of interfaces........................................................................................ 17
2.5.1 Control PC interfaces............................................................................................ 19
2.5.1.1 Motherboard D3076-K PC interfaces.................................................................... 19
2.6 Cooling................................................................................................................... 22
2.7 Intended use and misuse...................................................................................... 23
3 Safety......................................................................................................... 25
3.1 General.................................................................................................................. 25
3.1.1 Liability................................................................................................................... 25
3.1.2 EC declaration of conformity and declaration of incorporation............................ 25
3.1.3 Terms in the “Safety” chapter............................................................................... 26
3.2 Personnel............................................................................................................... 29
3.3 Workspace, safety zone and danger zone........................................................... 30
3.3.1 Determining stopping distances............................................................................ 30
3.4 Triggers for stop reactions.................................................................................... 30
3.5 Safety functions..................................................................................................... 31
3.5.1 Overview of the safety functions.......................................................................... 31
3.5.2 Safety controller..................................................................................................... 32
3.5.3 Selecting the operating mode............................................................................... 32
3.5.4 “Operator safety” signal......................................................................................... 33
3.5.5 EMERGENCY STOP device................................................................................. 34
3.5.6 Logging off from the higher-level safety controller............................................... 34
3.5.7 External EMERGENCY STOP device.................................................................. 35
3.5.8 Enabling device..................................................................................................... 35
3.5.9 External enabling device....................................................................................... 37
3.5.10 External safe operational stop.............................................................................. 37
3.5.11 External safety stop 1 and external safety stop 2............................................... 37
3.5.12 Velocity monitoring in T1....................................................................................... 37
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KR C4 compact
3.6 Additional protective equipment............................................................................ 38

3.6.1 Jog mode............................................................................................................... 38
3.6.2 Software limit switches.......................................................................................... 38
3.6.3 Mechanical end stops........................................................................................... 38
3.6.4 Mechanical axis limitation (optional)..................................................................... 38
3.6.5 Options for moving the manipulator without drive energy................................... 39
3.6.6 Labeling on the industrial robot............................................................................ 39
3.6.7 External safeguards............................................................................................... 40
3.7 Overview of operating modes and safety functions............................................. 40
3.8 Safety measures.................................................................................................... 41
3.8.1 General safety measures...................................................................................... 41
3.8.2 IT security.............................................................................................................. 42
3.8.3 Transportation........................................................................................................ 43
3.8.4 Start-up and recommissioning.............................................................................. 43
3.8.4.1 Checking machine data and safety configuration................................................ 45
3.8.4.2 Start-up mode........................................................................................................ 47
3.8.5 Manual mode......................................................................................................... 49
3.8.6 Simulation.............................................................................................................. 50
3.8.7 Automatic mode..................................................................................................... 50
3.8.8 Maintenance and repair........................................................................................ 50
3.8.9 Decommissioning, storage and disposal.............................................................. 52
3.8.10 Safety measures for single point of control......................................................... 52
4 Technical data.......................................................................................... 55
4.1 Dimensions............................................................................................................ 57
4.2 Cabinet Interface Board, Small Robot.................................................................. 58
4.3 Dimensions of the smartPAD holder (optional).................................................... 59
4.4 Dimensions of handle brackets............................................................................. 59
4.5 Plates and labels................................................................................................... 59
4.6 REACH duty to communicate information acc. to Art. 33................................... 61
5 Planning.................................................................................................... 63
5.1 Electromagnetic compatibility (EMC).................................................................... 63
5.2 Installation conditions............................................................................................ 64
5.3 Connection conditions........................................................................................... 65
5.4 PE equipotential bonding...................................................................................... 66
5.5 Power supply connection...................................................................................... 67
5.6 Safety interface X11.............................................................................................. 67
5.6.1 Contact diagram for connector X11...................................................................... 67
5.6.2 X11 safety interface............................................................................................... 68
5.6.3 Wiring example for E-STOP circuit and safeguard.............................................. 71
5.6.4 Wiring example for safe inputs and outputs........................................................ 73
5.7 Safety functions via Ethernet safety interface...................................................... 75
5.7.1 Schematic circuit diagram for enabling switches................................................. 80
5.7.2 SafeOperation via Ethernet safety interface (optional)........................................ 80
5.7.3 X66 Ethernet interface (RJ45).............................................................................. 84
5.8 Mastering test........................................................................................................ 85
5.9 X65 EtherCAT interface........................................................................................ 85
5.10 X69 KUKA Service Interface................................................................................. 86

KR C4 compact
5.11 Performance level.................................................................................................. 87

5.11.1 PFH values of the safety functions...................................................................... 87
6 Transportation.......................................................................................... 91
6.1 Transporting the robot controller........................................................................... 91
7 Start-up and recommissioning............................................................... 93

7.1 Start-up overview................................................................................................... 93
7.2 Installing the robot controller................................................................................. 94
7.3 Connecting the equipotential bonding (PE).......................................................... 94
7.4 Connecting the connecting cables........................................................................ 95
7.4.1 Motor connector X20............................................................................................. 95
7.4.2 X21 Data cable...................................................................................................... 96
7.5 Plugging in the KUKA smartPAD.......................................................................... 96
7.6 Reversing the battery discharge protection measures......................................... 97
7.7 Connecting the robot controller to the power supply........................................... 97
7.7.1 Connecting the robot controller to the power supply with a mains connector.... 97
7.7.2 Connecting the robot controller to the power supply without a mains connec-
tor........................................................................................................................... 98
7.8 Configuring and connecting connector X11.......................................................... 98
7.9 Switching on the robot controller.......................................................................... 99
8 Operation.................................................................................................. 101
8.1 KUKA smartPAD teach pendant........................................................................... 101
8.1.1 smartPAD............................................................................................................... 101
8.1.1.1 Front of smartPAD................................................................................................. 101
8.1.1.2 Rear of smartPAD................................................................................................. 103
8.1.2 smartPAD-2............................................................................................................ 104
8.1.3 Disconnecting and connecting the smartPAD...................................................... 104
9 Maintenance.............................................................................................. 107
9.1 Maintenance symbols............................................................................................ 107
9.2 Checking CCU_SR relay outputs......................................................................... 109
9.3 Cleaning the robot controller................................................................................. 110
10 Repair........................................................................................................ 113
10.1 Repair and procurement of spare parts............................................................... 113
10.2 Exchanging the motherboard................................................................................ 113
10.2.1 Removing the housing cover................................................................................ 114
10.2.2 Removing the fan holder from the control box.................................................... 115
10.2.3 Exchanging the motherboard................................................................................ 116
10.2.4 Installing the motherboard..................................................................................... 116
10.2.5 Installing the fan holder on the control box......................................................... 117
10.2.6 Installing the housing cover.................................................................................. 118
10.2.7 Concluding work.................................................................................................... 118
10.3 Exchanging the motherboard battery.................................................................... 119
10.3.2 Removing the motherboard battery...................................................................... 120
10.3.3 Inserting the motherboard battery......................................................................... 121
10.3.5 Concluding work.................................................................................................... 122

KR C4 compact
10.4 Exchanging the RAM............................................................................................ 122

10.4.2 Removing RAM..................................................................................................... 124
10.4.3 Inserting RAM........................................................................................................ 125
10.4.5 Concluding work.................................................................................................... 125
10.5 Exchanging the hard drive.................................................................................... 126
10.5.2 Removing the hard drive....................................................................................... 127
10.5.3 Installing the hard drive......................................................................................... 128
10.5.5 Concluding work.................................................................................................... 129
10.6 Exchanging the CCU sr........................................................................................ 129
10.6.2 CCU sr connections.............................................................................................. 131
10.6.3 Removing the CCU sr........................................................................................... 133
10.6.4 Installing the CCU sr............................................................................................. 133
10.6.6 Concluding work.................................................................................................... 135
10.7 Exchanging the battery......................................................................................... 135
10.7.2 Removing the battery............................................................................................ 137
10.7.3 Inserting the battery.............................................................................................. 137
10.7.4 Battery storage...................................................................................................... 138
10.7.6 Concluding work.................................................................................................... 139
10.8 Exchanging the network card............................................................................... 139
10.8.2 Removing the network card.................................................................................. 141
10.8.3 Installing a network card....................................................................................... 142
10.8.5 Concluding work.................................................................................................... 143
10.9 Exchanging the power supply unit........................................................................ 143
10.9.2 Removing the power supply unit.......................................................................... 145
10.9.3 Installing the power supply unit............................................................................ 145
10.9.5 Concluding work.................................................................................................... 146
10.10 Exchanging the mains filter................................................................................... 146
10.10.1 Removing the control box from the drive box...................................................... 148
10.10.2 Removing the mains filter..................................................................................... 148
10.10.3 Installing the mains filter....................................................................................... 149
10.10.4 Assembling control box and drive box................................................................. 149
10.10.5 Concluding work.................................................................................................... 150
10.11 Exchanging the mains filter with plug-in connector............................................. 151
10.11.1 Removing the mains filter with plug-in connector................................................ 152
10.11.2 Installing the mains filter with plug-in connector.................................................. 153
10.11.3 Concluding work.................................................................................................... 154
10.12 Exchanging the control box fans.......................................................................... 154

KR C4 compact

10.12.2 Removing the control box fans............................................................................. 156
10.12.3 Installing the control box fans............................................................................... 156
10.12.5 Concluding work.................................................................................................... 158
10.13 Exchanging the drive box fans............................................................................. 158
10.13.2 Removing the drive box fan.................................................................................. 160
10.13.3 Installing the drive box fan.................................................................................... 161
10.13.5 Concluding work for exchange of drive box fan.................................................. 163
10.14 Exchanging the KPP sr......................................................................................... 163
10.14.2 Removing the KPP sr........................................................................................... 165
10.14.3 Installing the KPP sr............................................................................................. 166
10.14.5 Concluding work.................................................................................................... 167
10.15 Exchanging the KSP sr + heat exchanger........................................................... 168
10.15.2 Removing the KSP sr + heat exchanger............................................................. 170
10.15.3 Installing the KSP sr + heat exchanger............................................................... 170
10.15.5 Concluding work.................................................................................................... 172
10.16 Exchanging the brake resistor.............................................................................. 172
10.16.2 Removing the brake resistor................................................................................. 174
10.16.3 Installing the brake resistor................................................................................... 175
10.16.5 Concluding work.................................................................................................... 176
10.17 Installing the KUKA System Software (KSS) ...................................................... 177
11 Troubleshooting....................................................................................... 179
11.1 LED display on Cabinet Control Unit, Small Robot............................................. 179
11.2 Fuses on the Cabinet Control Unit, Small Robot................................................ 183
12 Decommissioning, storage and disposal............................................. 187

12.1 Decommissioning................................................................................................... 187
12.2 Storage.................................................................................................................. 187
12.3 Disposal................................................................................................................. 188
13 Appendix................................................................................................... 189
13.1 Tightening torques................................................................................................. 189
13.2 Applied standards and regulations....................................................................... 189
14 KUKA Service........................................................................................... 193

14.1 Requesting support............................................................................................... 193
14.2 KUKA Customer Support...................................................................................... 193
Index 195

KR C4 compact

KR C4 compact
Introduction
1 Introduction
1.1 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 KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.
1.2 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 (if used)
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts overview in KUKA Xpert
Each of these sets of instructions is a separate document.
1.3 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.

Introduction KR C4 compact
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.
1.4 Trademarks
• Windows is a trademark of Microsoft Corporation.
• EtherCAT® is a registered trademark and patented tech-

nology, licensed by Beckhoff Automation GmbH, Germany.
• CIP Safety® is a trademark of ODVA.
1.5 Terms used
The overview may contain terms symbols that are not relevant for this
document.
Term Description
CIP Safety Common Industrial Protocol Safety

CIP Safety is an Ethernet/IP-based safety interface for connecting a
safety PLC to the robot controller (PLC = master, robot controller =
slave).
CCU_SR Cabinet Control Unit, Small Robot
CIB_SR Cabinet Interface Board, Small Robot
Dual NIC Dual Network Interface Card

Dual-port network card
EDS Electronic Data Storage

(memory card)
EMD Electronic Mastering Device
EMC Electromagnetic compatibility
KCB KUKA Controller Bus

KR C4 compact
Introduction
KEB KUKA Extension Bus
KEI KUKA EtherCAT Interface
KLI KUKA Line Interface

Ethernet interface of the robot controller for external communication
KOI KUKA Operator Panel Interface
KONI KUKA Option Network Interface

Interface for KUKA options
KPC KUKA control PC
KPP_SR KUKA Power Pack, Small Robot

Drive power supply with drive controller
KSB KUKA System Bus

Field bus for internal networking of the controllers
KSP_SR KUKA Servo Pack, Small Robot

Drive controller
KSS KUKA System Software
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
Manipulator The robot arm and the associated electrical installations
PMB_SR Power Management Board, Small Robot
RDC Resolver Digital Converter

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).
SATA connections Data bus for exchanging data between the processor and the hard
drive
Transmission request signal
smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:
• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
The designation “KUKA smartPAD” or “smartPAD” refers to both
models unless an explicit distinction is made.
USB Universal Serial Bus

Bus system for connecting additional devices to a computer
EA External axis (linear unit, Posiflex)

Introduction KR C4 compact

KR C4 compact
Product description
2 Product description
2.1 Description of the industrial robot
The industrial robot consists of the following components:

• Manipulator
• Robot controller
• smartPAD teach pendant
• Connecting cables
• Software
• Options, accessories
Fig. 2-1: Example of an industrial robot
1 Manipulator
2 Control panel
3 Connecting cable for smartPAD
4 Robot controller
5 Connecting cable, data cable
6 Connecting cable, motor cable
7 Device connection cable
2.2 Overview of the robot controller
The robot controller is used for controlling the following systems:

• KUKA small robot
The robot controller consists of the following components:
• Control PC
• Power unit
• Safety logic
• smartPAD control panel
• Connection panel

KR C4 compact
The robot controller can be installed in a 19" rack.

Product description
Fig. 2-2: Overview of KR C4 compact
1 Control unit (control box)

2 Power unit (drive box)
2.3 Control box
The control box consists of the following components:
Fig. 2-3: Overview of control box
1 Fan 7 Device switch

2 Hard drive 8 Interfaces
3 Low-voltage power supply unit 9 Options
4 Memory card (EDS) 10 Motherboard
5 Cabinet Control Unit, Small 11 Batteries
Robot (CCU_SR)
6 Interfaces in the cover

KR C4 compact
Product description
2.3.1 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)
• Optional modules, e.g. field bus cards
Functions
The control PC (KPC) is responsible for the following functions of the ro-
bot controller:
• Graphical user interface
• Program creation, correction, archiving, and maintenance
• Sequence control
• Path planning
• Control of the drive circuit
• Monitoring
• Safety equipment
• Communication with external periphery (other controllers, host comput-
ers, PCs, network)
2.3.2 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
‒ 4 floating outputs
‒ 9 safe inputs
‒ Teach pendant plugged in
‒ Mastering test
• 6 Fast Measurement inputs for customer applications
• Power supply fan monitoring

Product description KR C4 compact
• Temperature sensing:
‒ Control box internal temperature
• The following components are connected to the KPC via the KUKA
Controller Bus:
‒ Drive box
‒ Resolver Digital Converter
• The following operator panels and service devices are connected to
the control PC via the KUKA System Bus:
‒ KUKA Operator Panel Interface
• Diagnostic LEDs
• Electronic Data Storage interface
Power supply with battery backup
• Drive box
• KUKA smartPAD
• Multi-core control PC
• Resolver Digital Converter (RDC)
Power supply without battery backup
• Motor brakes
• Customer interface
2.3.3 Low-voltage power supply unit
Description
The low-voltage power supply unit provides power to the components of

the robot controller.
A green LED indicates the operating state of the low-voltage power supply
unit.
2.3.4 Batteries
Description
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 and the charge is checked and in-
dicated.
2.3.5 Mains filter
Description
The mains filter (interference suppressor filter) suppresses interference

voltages on the power cable.
2.4 Drive box (Drive Configuration (DC))
The drive box consists of the following components:

KR C4 compact
Product description
Fig. 2-4: Overview of drive box
1 Motor connector X20 4 Mains filter

2 Brake resistor 5 KUKA Servo Pack, Small Ro-
bot (KSP_SR)
3 KUKA Power Pack, Small Ro- 6 Fans
bot (KPP_SR)
Functions
The drive box performs the following functions:

• Generation of the intermediate circuit voltage
• Control of the motors
• Control of the brakes
• Checking of intermediate circuit voltage in braking mode
2.5 Description of interfaces
Overview
The connection panel of the robot controller consists as standard of con-

nections for the following cables:
• Device connection cable
• Motor cable, data cable
• smartPAD cable
• Peripheral cables
The configuration of the connection panel varies according to the custom-
er-specific version and the options required.
Note
The following safety interfaces can be configured in the robot controller:

• Discrete safety interface X11
• Ethernet safety interface X66
‒ PROFIsafe KLI or
‒ CIP Safety KLI

The discrete safety interface X11 and the Ethernet safety interface X66
cannot be connected and used together.
Only one of the safety interfaces can be used at a time.
The configuration of the connection panel varies according to customer re-

quirements and options. In this documentation, the robot controller is de-
scribed with the maximum configuration.
Connection panel
Fig. 2-5: KR C4 compact interfaces
1 X11 Safety interface (option)

2 smartPAD connection X19
3 X65 Extension interface
4 X69 Service interface
5 X21 Manipulator interface
6 Ethernet safety interface X66
7 K1 power supply connection
8 Motor connector X20
9 Control PC interfaces
Only safety interface X11 or Ethernet safety interface X66

(PROFIsafe/CIP Safety) can be configured.
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.
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.

KR C4 compact
Product description
2.5.1 Control PC interfaces
Motherboards
The following motherboard variants can be installed in the control PC:

• D3076-K
• D3236-K
• D3445-K
2.5.1.1 Motherboard D3076-K PC interfaces
Overview
Fig. 2-6: 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


Slot assignment
Fig. 2-7: 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 PCI Field bus
4 PCI Field bus
5 PCIe not available
7 PCIe LAN Dual NIC network card
Overview

3 2 USB 3.0 ports
4 DVI-I
5 4 USB 2.0 ports

KR C4 compact
Product description
Slot assignment
Fig. 2-9: Motherboard slot assignment
The PC slots can be fitted with the following plug-in cards:

1 PCI Field bus
2 PCI Field bus
3 - Not available
4 - Not available
5 - Not available
6 - Not available
7 - Not available
Overview

3 2 USB 3.0 ports

4 DVI-D
5 Display port
6 4 USB 2.0 ports
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.

Slot assignment
Fig. 2-11: Slot assignment, motherboard D3445-K

1 PCI Field bus
2 PCI Field bus
3 - not available
4 - not available
6 - not available
7 - not available
2.6 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!

KR C4 compact
Product description
Cooling circuit, control box
Fig. 2-12: Cooling circuit, control box
1 Air inlet 3 Air outlet

2 Fans
Cooling circuit, drive box
Fig. 2-13: Cooling circuit, drive box
1 Air inlet 3 Air outlet

2 Fans
2.7 Intended use and misuse
Use
The robot controller is intended solely for operating the following compo-
nents:
• KUKA industrial robots
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. This includes e.g.:
• Use as a climbing aid
• Operation outside the permissible operating parameters
• Use in potentially explosive environments
• Use in underground mining


KR C4 compact
Safety
3 Safety
3.1 General
3.1.1 Liability
The device described in this document is either an industrial robot or a

component thereof.
Components of the industrial robot:
• Manipulator
• Robot controller
• Teach pendant
• Connecting cables
• External axes (optional)
e.g. linear unit, turn-tilt table, positioner
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in 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 intended use and only by safety-conscious persons who
are fully aware of the risks involved in its operation. Use of the industrial
robot is subject to compliance with this document and with the declaration
of incorporation supplied together with the industrial robot. Any functional
disorders, especially those affecting safety, must be rectified immediately.
Safety information
Information about safety may not be construed against the manufacturer.

Even if all safety instructions are followed, this is not a guarantee that the
industrial robot will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the au-
thorization of the manufacturer. Unauthorized modifications will result in
the loss of warranty and liability claims.
Additional components (tools, software, etc.), not supplied by the manufac-
turer, may be integrated into the industrial robot. The user is liable for any
damage these components may cause to the industrial robot or to other
material property.
In addition to the Safety chapter, this document contains further safety in-
structions. These must also be observed.
3.1.2 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:

Safety KR C4 compact
• 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.
3.1.3 Terms in the “Safety” chapter
STOP 0, STOP 1 and STOP 2 are the stop definitions according to

EN 60204-1:2018.
Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may
move. The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
User The user of the industrial robot can be the management, employer
or delegated person responsible for use of the industrial robot.
Service life The service life of a safety-relevant component begins at the time
of delivery of the component to the customer.
The service life is not affected by whether the component is used
or not, as safety-relevant components are also subject to aging dur-
ing storage.

KR C4 compact
Safety
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safe operational stop The safe operational stop is a standstill monitoring function. It does
not stop the robot motion, but monitors whether the robot axes are
stationary. If these are moved during the safe operational stop, a
safety STOP 0 is triggered.
The safe operational stop can also be triggered externally.
When a safe operational stop is triggered, the robot controller sets
an output to the field bus. The output is set even if not all the axes
were stationary at the time of triggering, thereby causing a safety
STOP 0 to be triggered.
Safety STOP 0 A stop that is triggered and executed by the safety controller. The
safety controller immediately switches off the drives and the power
supply to the brakes.
Note: This stop is called safety STOP 0 in this document.
Safety STOP 1 A stop that is triggered and monitored by the safety controller. The
braking operation is carried out by the non-safety-oriented section
of the robot controller and monitored by the safety controller. As
soon as the manipulator has stopped, the safety controller deacti-
vates the drives and the power supply of the brakes.
When a safety STOP 1 is triggered, the robot controller sets an
output to the field bus.
The safety STOP 1 can also be triggered externally.
Safety STOP 2 A stop that is triggered and monitored by the safety controller. The
braking operation is carried out by the non-safety-oriented section
of the robot controller and monitored by the safety controller. The
drives remain activated and the brakes released. As soon as the
manipulator is at a standstill, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an
output to the field bus.
The safety STOP 2 can also be triggered externally.
Safety options Generic term for options which make it possible to configure addi-
tional safe monitoring functions in addition to the standard safety
functions.
Example: SafeOperation

smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:
• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
For robot controllers of the KR C5 series, only the model “smart-
PAD-2” is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to both models unless an explicit distinc-
tion is made.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.
• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking.
• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 - DRS in this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
System integrator The system integrator is responsible for safely integrating the indus-
(plant integrator) trial robot into a complete system and commissioning it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. e.g. KUKA linear unit, turn-tilt table,
Posiflex

KR C4 compact
Safety
3.2 Personnel
The following persons or groups of persons are defined for the industrial
robot:
• User
• Personnel
Qualification of personnel
Work on the system must only be performed by personnel that is able
to assess the tasks to be carried out and detect potential hazards.
Death, severe injuries or damage to property may otherwise result. The
following qualifications are required:
• Adequate specialist training, knowledge and experience
• Knowledge of the relevant operating or assembly instructions, knowl-
edge of the relevant standards
• All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.
User
The user must observe the labor laws and regulations. This includes e.g.:
• The user must comply with his monitoring obligations.

• The user must carry out briefing at defined intervals.
• The user must comply with the regulations relating to personal protec-
tive equipment (PSA).
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
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.
3.3 Workspace, safety zone and danger zone
Workspaces are to be restricted to the necessary minimum size. A work-

space must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone.
In the case of a stop, the manipulator and external axes (optional) are
braked and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). It must be safeguarded by
means of physical safeguards to prevent danger to persons or the risk of
material damage.
3.3.1 Determining stopping distances
The system integrator’s risk assessment may indicate that the stopping
distances must be determined for an application. In order to determine the
stopping distances, the system integrator must identify the safety-relevant
points on the programmed path.
When determining the stopping distances, the robot must be moved with
the tool and loads which are also used in the application. The robot must
be at operating temperature. This is the case after approx. 1 h in normal
operation.
During execution of the application, the robot must be stopped at the point
from which the stopping distance is to be calculated. This process must
be repeated several times with a safety stop 0 and a safety stop 1. The
least favorable stopping distance is decisive.
A safety stop 0 can be triggered by a safe operational stop via the safety
interface, for example. If a safety option is installed, it can be triggered,
for instance, by a space violation (e.g. the robot exceeds the limit of an
activated workspace in Automatic mode).
A safety stop 1 can be triggered by pressing the EMERGENCY STOP de-
vice on the smartPAD, for example.
3.4 Triggers for stop reactions
Stop reactions of the industrial robot are triggered in response to operator

actions or as a reaction to monitoring functions and error messages. The
following table shows the different stop reactions according to the operat-
ing mode that has been set.
Trigger T1, T2 AUT, AUT EXT
Start key released STOP 2 -
STOP key pressed STOP 2
Drives OFF STOP 1

KR C4 compact
Safety
Trigger T1, T2 AUT, AUT EXT
$MOVE_ENABLE input STOP 2
drops out
Power switched off via STOP 0
main switch or device
switch
Or power failure
Internal error in non-safe- STOP 0 or STOP 1
ty-oriented part of the ro-
(dependent on the cause of the error)
bot controller
Operating mode changed Safety stop 2
during operation
Safety gate opened (op- - Safety stop 1
erator safety)
Enabling switch released Safety stop 2 -
Enabling switch pressed Safety stop 1 -
fully down or error
E-STOP pressed Safety stop 1
Error in safety controller Safety stop 0
or periphery of the safety
controller
3.5 Safety functions
3.5.1 Overview of the safety functions
The following safety functions are present in the industrial robot:

• Operating mode selection
• Operator safety (= connection for the monitoring of physical safe-
guards)
• EMERGENCY STOP device
• Enabling device
• External safe operational stop
• External safety stop 1
• External safety stop 2
• Velocity monitoring in T1
The safety functions of the industrial robot meet the following require-
ments:
• Category 3 and Performance Level d in accordance with EN ISO
13849-1
The requirements are only met on the following condition, however:
• The EMERGENCY STOP device is pressed at least once every 12
months.
• The enabling device is checked at least once every 12 months.
(>>> "Function test" Page 36)

DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.
Integrate industrial robot into safety system of the overall system

During system planning, the safety functions of the overall system must
be planned and designed. Death, severe injuries or damage to property
may otherwise result.
• The industrial robot must be integrated into the safety system of the
overall system.
3.5.2 Safety controller
The safety controller is a unit inside the control PC. It links safety-relevant
signals and safety-relevant monitoring functions.
Safety controller tasks:
• Switching off the drives; applying the brakes
• Monitoring the braking ramp
• Standstill monitoring (after the stop)
• Velocity monitoring in T1
• Evaluation of safety-relevant signals
• Setting of safety-oriented outputs
3.5.3 Selecting the operating mode
Operating modes
The industrial robot can be operated in the following modes:

• Manual Reduced Velocity (T1)
• Manual High Velocity (T2)
• Automatic (AUT)
• Automatic External (AUT EXT)
Do not change the operating mode while a program is running. If the

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

KR C4 compact
Safety
Operating
Use Velocities
mode
• Program verification:
Programmed velocity, maxi-
For test operation,
mum 250 mm/s
T1 programming and
teaching • Jog mode:
Jog velocity, maximum
250 mm/s
• Program verification:
T2 For test operation Programmed velocity
• Jog mode: Not possible
For industrial robots • Program operation:

AUT without higher-level Programmed velocity
controllers • Jog mode: Not possible
For industrial robots • Program operation:

AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC • Jog mode: Not possible
Mode selector switch
The user can change the operating mode via the connection manager.
The connection manager is a view that is called by means of the mode
selector switch on the smartPAD.
The mode selector switch may be one of the following variants:
• With key
It is only possible to change operating mode if the key is inserted.
• Without key
WARNING
Danger to life and limb due to mode selector switch without
access restriction
If the smartPAD is equipped with a mode selector switch without a key,
all persons can operate the mode selector switch, irrespective of their
field of activity or qualifications. Death, severe injuries or damage to
property may result.
• An additional device must be installed to ensure that the mode se-
lector switch can only be operated by a restricted group of people.
• The device itself must not trigger motions of the industrial robot or
other hazards.
3.5.4 “Operator safety” signal
The “operator safety” signal is used for monitoring physical safeguards,

e.g. safety gates. Automatic operation is not possible without this signal.
In the event of a loss of signal during automatic operation (e.g. safety
gate is opened), the manipulator stops with a safety stop 1.
Operator safety is not active in modes T1 (Manual Reduced Velocity) and
T2 (Manual High Velocity).

WARNING
Danger to life and limb due to resumed automatic operation with-
out adequate acknowledgement
Following loss of the “Operator safety” signal, it must not be possible to
restart automatic operation by merely closing the safeguard. Otherwise,
for example, the safety gate could close unintentionally, thereby causing
automatic operation to resume while there are persons in the danger
zone. Death, severe injuries or damage to property may result.
• Automatic operation must not be resumed until the safeguard has
been closed and the closing has been acknowledged.
• The acknowledgement must be designed in such a way that an ac-
tual check of the danger zone can be carried out first. Other ac-
knowledgement functions (e.g. an acknowledgement which is auto-
matically triggered by closure of the safeguard) are not permitted.
3.5.5 EMERGENCY STOP device
The EMERGENCY STOP device for the industrial robot is the EMERGEN-
CY STOP device on the smartPAD. The device must be pressed in the
event of a hazardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP device is
pressed:
• The manipulator and any external axes (optional) are stopped with a
safety stop 1.
Before operation can be resumed, the EMERGENCY STOP device must
be turned to release it.
WARNING
Danger to life and limb due to tools and equipment without EMER-
GENCY STOP
If tools and other equipment connected to the robot are not integrated
into the EMERGENCY STOP circuit, this can result in death, severe in-
juries or damage to property.
• Integrate tools and other equipment into the EMERGENCY STOP
circuit if they could constitute a potential hazard.
There must always be at least one external EMERGENCY STOP device

installed. This ensures that an EMERGENCY STOP device is available
even when the smartPAD is disconnected.
(>>> 3.5.7 "External EMERGENCY STOP device" Page 35)
3.5.6 Logging off from the higher-level safety controller
If the robot controller is connected to a higher-level safety controller, this

connection will inevitably be terminated in the following cases:
• Switching off the voltage via the main switch or device switch of the
robot controller
Or power failure
• Shutdown of the robot controller via the smartHMI
• Activation of a WorkVisual project in WorkVisual or directly on the ro-
bot controller
• Changes to Start-up > Network configuration
• Changes to Configuration > Safety configuration
• I/O drivers > Reconfigure

KR C4 compact
Safety
• Restoration of an archive
Effect of the interruption:
• If a discrete safety interface is used, this triggers an EMERGENCY
STOP for the overall system.
• If the Ethernet interface is used, the KUKA safety controller generates
a signal that prevents the higher-level controller from triggering an
EMERGENCY STOP for the overall system.
Take Ethernet safety interface into consideration in risk assess-

ment
Failure to take the Ethernet safety interface into consideration in the risk
assessment may result in death, severe injuries or damage to property.
• In his risk assessment, the system integrator must take into consid-
eration whether the fact that switching off the robot controller does
not trigger an EMERGENCY STOP of the overall system could con-
stitute a hazard and, if so, how this hazard can be countered.
WARNING
Danger to life and limb due to smartPAD on controller that has
been switched off
If a robot controller is switched off, the EMERGENCY STOP device on
the smartPAD is not operational. There is a risk of operational and non-
operational EMERGENCY STOP devices becoming interchanged.
Death, severe injuries or damage to property may result.
• Cover smartPADs on controllers that have been switched off or re-
move them from the system.
3.5.7 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.
There must always be at least one external EMERGENCY STOP device
installed. This ensures that an EMERGENCY STOP device is available
even when the smartPAD is disconnected.
External EMERGENCY STOP devices are connected via the customer in-
terface. External EMERGENCY STOP devices are not included in the
scope of supply of the industrial robot.
3.5.8 Enabling device
The enabling devices of the industrial robot are the enabling switches on
the smartPAD.
• smartPAD: 3 enabling switches
• smartPAD-2: 4 enabling switches
The enabling switches have 3 positions:
• Not pressed
• Center position
• Fully pressed (panic position)
In the test modes, the manipulator can only be moved if at least one of
the enabling switches is held in the center position.

KR C4 compact
It is possible to hold several enabling switches in the center position si-

Safety
multaneously. This makes it possible to adjust grip from one enabling

switch to another one.
In the test modes, the manipulator can be stopped in the following ways:
• Press at least one enabling switch down fully.
Pressing an enabling switch down fully triggers a safety stop 1.
• Or release all enabling switches.
Releasing all (!) enabling switches held in the center position triggers
a safety stop 2.
WARNING
Danger to life and limb due to lack of reaction when an enabling
switch is released
Releasing one of multiple enabling switches held in the center position
does not trigger a stop reaction.
If multiple switches are held in the center position, the robot controller
cannot distinguish whether one of them was intentionally released or if it
was unintentionally released as the result of an accident.
• Create awareness for the hazard.
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.
• Release the Start key.
WARNING
Danger to life and limb due to manipulation of enabling switches
The enabling switches must not be held down by adhesive tape or other
means or tampered with in any other way. Death, severe injuries or
damage to property may result.
• Carry out a visual inspection of the enabling switches.
• Rectify tampering or remove any foreign bodies.
Function test
The function of the enabling switches must be tested in the following ca-
ses:
• Following initial start-up or recommissioning of the industrial robot
• After a software update
• After disconnecting and reconnecting a smartPAD (the same smart-
PAD or another one)
• The test must be carried out at least once every 12 months.
To test, perform the following steps separately for each enabling switch:
1. Move the manipulator in a test mode.
2. While the manipulator is moving, press the enabling switch down fully
and hold it down for 3 seconds.
The test is passed in the following case:
• The manipulator stops.
• And: No error message for the enabling device is displayed (Enabling
switch error or similar).
If the test has not been passed for one or more enabling switches, the
smartPAD must be exchanged and the test must be performed again.

KR C4 compact
Safety
3.5.9 External enabling device
External enabling devices are required if it is necessary for more than one
person to be in the danger zone of the industrial robot.
The function of the external enabling switches must be tested at least
once every 12 months.
Which interface can be used for connecting external enabling devices is
described in the “Planning” chapter of the robot controller operating in-
structions and assembly instructions.
External enabling devices are not included in the scope of supply of the
industrial robot.
3.5.10 External safe operational stop
The safe operational stop can be triggered via an input on the customer
interface. The state is maintained as long as the external signal is FALSE.
If the external signal is TRUE, the manipulator can be moved again. No
acknowledgement is required.
3.5.11 External safety stop 1 and external safety stop 2
Safety stop 1 and safety stop 2 can be triggered via an input on the cus-
tomer interface. The state is maintained as long as the external signal is
FALSE. If the external signal is TRUE, the manipulator can be moved
again. No acknowledgement is required.
If interface X11 is selected as the customer interface, only the signal
Safety stop 2 is available.
3.5.12 Velocity monitoring in T1
In T1 mode, the velocity is safely monitored on both an axis-specific and

Cartesian basis.
• Applicable up to and including System Software 8.5.7:

For customer kinematic systems (CKs), only the axis-specific
velocity is safely monitored in T1 mode. The Cartesian position on
the flange is only available for KUKA kinematic systems using safe
technology.
• Applicable for System Software 8.5.8 or higher:
For all kinematic systems, the axis-specific velocity is safely moni-
tored in T1 mode. The Cartesian velocity is safely monitored in T1 if
the associated setting is activated in the safety configuration.
Axis-specific monitoring
If an axis exceeds its velocity limit, a safety stop 0 is triggered.

• Default limit value for rotational axes: 30°/s
• Default limit value for linear axes: 250 mm/s
From System Software 8.3 onwards, the axis-specific monitoring can be

configured using the Maximum velocity T1 parameter. Further informa-
tion about this can be found in the Operating and Programming In-
structions for System Integrators documentation for the System Soft-
ware.

Cartesian monitoring
The Cartesian monitoring refers to the velocity at the flange. If a limit val-
ue is exceeded, a safety stop 0 is triggered.
• Default limit value: 250 mm/s
If an additional safety option (e.g. SafeOperation) is used, the limit value
can be configured. It can be reduced, but not increased.
3.6 Additional protective equipment
3.6.1 Jog mode
In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual

High Velocity), the robot controller can only execute programs in jog
mode. This means that it is necessary to hold down an enabling switch
and the Start key in order to execute a program.
• Releasing the enabling switch triggers a safety stop 2.
• Pressing the enabling switch down fully (panic position) triggers a
safety stop 1.
• Releasing the Start key triggers a STOP 2.
3.6.2 Software limit switches
The axis ranges of all manipulator and positioner axes are limited by
means of adjustable software limit switches. These software limit switches
only serve as machine protection and must be adjusted in such a way
that the manipulator/positioner cannot hit the mechanical end stops.
The software limit switches are set during commissioning of an industrial
robot.
Further information is contained in the operating and programming in-
structions.
3.6.3 Mechanical end stops
Depending on the robot variant, the axis ranges of the main and wrist ax-
es of the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.
WARNING
Danger to life and limb following collision with obstacle
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator can no
longer be operated safely. Death, injuries or damage to property may re-
sult.
• Put manipulator out of operation.
• KUKA must be consulted before it is put back into operation.
3.6.4 Mechanical axis limitation (optional)
Some manipulators can be fitted with mechanical axis limitation systems

in axes A1 to A3. The axis limitation systems restrict the working range to

KR C4 compact
the required minimum. This increases personal safety and protection of
Safety
the system.
In the case of manipulators that are not designed to be fitted with me-
chanical axis limitation, the workspace must be laid out in such a way that
there is no danger to persons or material property, even in the absence of
mechanical axis limitation.
If this is not possible, the workspace must be limited by means of photo-
electric barriers, photoelectric curtains or obstacles on the system side.
There must be no shearing or crushing hazards at the loading and trans-
fer areas.
This option is not available for all robot models. Information on specific
robot models can be obtained from the manufacturer.
3.6.5 Options for moving the manipulator without drive energy
Qualification of personnel with regard to behavior in emergency

situations
In emergencies or other exceptional situations, it may be necessary to
move the manipulator without drive energy.
• Personnel must be trained in how to move the manipulator without
drive energy.
Description
The following options are available for moving the manipulator without
drive energy after an accident or malfunction:
• Release device (optional)
The release device can be used for the main axis drive motors and,
depending on the robot variant, also for the wrist axis drive motors.
• Brake release device (option)
The brake release device is designed for robot variants whose motors
are not freely accessible.
• Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in
the low payload category. This is not necessary because the wrist ax-
es can be moved directly by hand.
Information about the options available for the various robot models and
about how to use them can be found in the assembly and operating in-
structions for the robot or can be requested from the manufacturer.
NOTICE
Damage to property due to moving the manipulator without drive
energy
Moving the manipulator without drive energy can damage the motor
brakes of the axes concerned.
• Only move the manipulator without drive energy in emergencies,
e.g. for rescuing persons.
• The motor must be replaced if the brake has been damaged.
3.6.6 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.

KR C4 compact
Labeling on the industrial robot consists of:

Safety
• 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.
3.6.7 External safeguards
The access of persons to the danger zone of the industrial robot must be
prevented by means of safeguards. It is the responsibility of the system
integrator to ensure this.
Physical safeguards must meet the following requirements:
• They meet the requirements of EN ISO 14120.

• They prevent access of persons to the danger zone and cannot be
easily circumvented.
• They are sufficiently fastened and can withstand all forces that are
likely to occur in the course of operation, whether from inside or out-
side the enclosure.
• They do not, themselves, represent a hazard or potential hazard.
• Prescribed clearances, e.g. to danger zones, are adhered to.
Safety gates (maintenance gates) must meet the following requirements:
• They are reduced to an absolute minimum.

• The interlocks (e.g. safety gate switches) are linked to the operator
safety input of the robot controller via safety gate switching devices or
safety PLC.
• Switching devices, switches and the type of switching conform to the
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 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.
3.7 Overview of operating modes and safety functions
The following table indicates the operating modes in which the safety
functions are active.

KR C4 compact
Safety
Safety functions T1 T2 AUT AUT EXT
Operator safety - - Active Active
EMERGENCY STOP device Active Active Active Active
Enabling device Active Active - -
Reduced velocity during
Active - - -
program verification
Jog mode Active Active - -
Software limit switches Active Active Active Active
3.8 Safety measures
3.8.1 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 or external axes to sag. If work is to be
carried out on a switched-off industrial robot, the manipulator and external
axes must first be moved into a position in which they are unable to move
on their own, whether the payload is mounted or not. If this is not possi-
ble, the manipulator and external axes must be secured by appropriate
means.
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.
DANGER
Danger to life and limb of persons under the robot arm
Sagging or falling parts can cause death or serious injuries. This applies
at all times, e.g. also for assembly tasks or with the controller switched
off.
• Never loiter under the robot arm.
CAUTION
Risk of burns from hot motors
The motors reach temperatures during operation which can cause
burns.
• Avoid contact.
• Take appropriate safety precautions, e.g. wear protective gloves.
smartPAD
The user must ensure that the industrial robot is only operated with the
smartPAD by authorized persons.

KR C4 compact
If more than one smartPAD is used in the overall system, it must be en-
Safety
sured that it is clearly recognizable which smartPAD is connected to which

industrial robot. They must not be interchanged.
WARNING
Danger to life and limb due to disconnected smartPAD
If a smartPAD is disconnected, its EMERGENCY STOP device is not
operational. There is a risk of connected and disconnected smartPADs
being interchanged. Death, injuries or damage to property may result.
• Remove the disconnected smartPAD from the system immediately.
• Store the disconnected smartPAD out of sight and reach of person-
nel working on the industrial robot.
The enabling switches on the smartPAD must be subjected to a function

test at least once every 12 months and in certain specific cases.
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 e.g. modifications of the
external axes or to the software and configuration settings.
Faults
The following tasks must be carried out in the case of faults in the indus-
trial robot:
• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
• Eliminate the fault and carry out a function test.
3.8.2 IT security
KUKA products must only be used in perfect technical condition in accord-

ance with their intended use and only by safety-conscious persons.
In particular, safety-conscious use includes being operated in an IT envi-
ronment which meets the current security-relevant standards and for
which there is an overall concept for IT security.
Take measures to ensure IT security
IT security involves not only aspects of information and data processing
as such, but also affects at least the following areas:
• Technology, organization, personnel, infrastructure
KUKA urgently recommends that users implement an information securi-
ty management system for their products which designs, coordinates
and monitors the tasks related to information security.

KR C4 compact
Sources for information about IT security for companies include:
Safety
• 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.
3.8.3 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.
External axis (optional)
The prescribed transport position of the external axis (e.g. KUKA linear
unit, turn-tilt table, positioner) must be observed. Transportation must be
carried out in accordance with the operating instructions or assembly in-
structions of the external axis.
3.8.4 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.
Changing default passwords
The KUKA System Software is supplied with default passwords for the
user groups. If the passwords are not changed, this enables unauthor-
ized persons to log on.
• Before start-up, change the passwords for the user groups.
• Only communicate the passwords to authorized personnel.
WARNING
Danger to life and limb due to incorrectly assigned cables
The robot controller is preconfigured for the specific industrial robot. The
manipulator and other components can receive incorrect data if they are
connected to a different robot controller. Death, severe injuries or dam-
age to property may result.
• Only connect the manipulator to the corresponding robot controller.

WARNING
Risk of fatal injury due to non-configured external axes
The robot controller cannot detect an external axis that is physically
connected, but not configured correctly in the software. It cannot exert
any torque nor any holding torque on this external axis. If the brakes re-
lease, uncontrolled motion can occur at this external axis as a result.
Death, severe injuries or damage to property may result.
• Ensure that external axes are correctly configured before an ena-
bling switch is pressed and the brakes are thus released.
Do not impair safety functions

Additional components (e.g. cables and hoses) not supplied by KUKA
may be integrated into the industrial robot. If the safety functions are not
taken into consideration, this may result in death, severe injuries or
damage to property.
• Additional components must not impair or disable safety functions.
NOTICE
Damage to property due to condensation
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form. This may result
in damage to property.
• Wait until the internal cabinet temperature has adapted to the ambi-
ent temperature in order to avoid condensation.
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 is no damage to the robot that could be attributed to external
forces.
WARNING
Danger to life and limb resulting from external forces
External forces, such as an impact or a collision, can cause non-
visible damage. For example, it can lead to a gradual loss of drive
power from the motor, resulting in unintended movements of the ma-
nipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
‒ In the case of damage, the affected components must be ex-
changed.
• There are no foreign bodies or defective or loose parts on the industri-

al robot.
• All required safety equipment is correctly installed and operational.

KR C4 compact
Safety
• 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 the following safety functions to en-
sure that they are functioning correctly:
• Local EMERGENCY STOP device

• External EMERGENCY STOP device (input and output)
• Enabling device (in the test modes)
• Operator safety
• All other safety-relevant inputs and outputs used
• Other external safety functions
3.8.4.1 Checking machine data and safety configuration
WARNING
Danger to life and limb due to incorrect data
The industrial robot must not be moved if incorrect machine data or an
incorrect controller configuration are loaded. Unforeseeable reactions
may occur. Death, severe injuries or damage to property may result.
• Only operate industrial robots with correct data.
• Following the start-up procedure, the practical tests for the machine
data must be carried out. The tool must be calibrated (either via an
actual calibration or through numerical entry of the data).
• Following modifications to the machine data, the safety configuration
must be checked.
• After activation of a WorkVisual project on the robot controller, the
safety configuration must be checked.
• If machine data are adopted when checking the safety configuration
(regardless of the reason for the safety configuration check), the prac-
tical tests for the machine data must be carried out.
• System Software 8.3 or higher: If the checksum or the activation code
of the safety configuration has changed, the safe axis monitoring func-
tions must be checked.
Up to and including System Software 8.5, the value in the safety con-
figuration is “Checksum”; for 8.6 and above, it is “Activation code”.
Information about checking the safety configuration and the safe axis
monitoring functions is contained in the Operating and Programming In-
structions for System Integrators.
If the practical tests are not successfully completed in the initial start-up,
KUKA Deutschland GmbH must be contacted.
If the practical tests are not successfully completed during a different pro-
cedure, the machine data and the safety-relevant controller configuration
must be checked and corrected.

General practical test
If practical tests are required for the machine data, this test must always
be carried out.
For 6-axis robots:
The following methods are available for performing the practical test:
• TCP calibration with the XYZ 4-point method
The practical test is passed if the TCP has been successfully calibra-
ted.
Or:
1. Align the TCP with a freely selected point. The point serves as a ref-
erence point.
• The point must be located so that reorientation is possible.
• The point must not be located on the Z axis of the FLANGE coor-
dinate system.
2. Move the TCP manually at least 45° once in each of the A, B and C
directions.
The movements do not have to be accumulative, i.e. after motion in
one direction it is possible to return to the original position before mov-
ing in the next direction.
The practical test is passed if the TCP does not deviate from the ref-
erence point by more than 2 cm in total.
For palletizing robots:
Palletizing robots, in this case, are either robots that can be used only as
palletizers from the start or robots operated in palletizing mode. The latter
must also be in palletizing mode during the practical test.
First part:
1. Mark the starting position of the TCP.
Also read and note the starting position from the Actual position –
Cartesian display on the smartHMI.
2. Jog the TCP in the X direction. The distance must be at least 20% of
the robot’s maximum reach. Determine the exact length via the Actual
position display.
3. Measure the distance covered and compare it with the distance value
displayed on the smartHMI. The deviation must be < 5%.
4. Repeat steps 1 and 2 for the Y direction and Z direction.
The first part of the practical test is passed if the deviation is < 5% in ev-
ery direction.
Second part:
• Rotate the tool manually about A by 45°: once in the plus direction,
once in the minus direction. At the same time, observe the TCP.
The second part of the practical test is passed if the position of the TCP
in space is not altered during the rotations.
Practical test for axes that are not mathematically coupled
If practical tests are required for the machine data, this test must be car-
ried out when axes are present that are not mathematically coupled.
1. Mark the starting position of the axis that is not mathematically cou-
pled.
Also read and note the start position from the Actual position display
on the smartHMI.

KR C4 compact
Safety
2. Move the axis manually by a freely selected path length. Determine
the path length from the Actual position display.
• Move linear axes a specific distance.
• Move rotational axes through a specific angle.
3. Measure the length of the path covered and compare it with the value
displayed on the smartHMI.
The practical test is passed if the values differ by no more than 5%.
4. Repeat the test for each axis that is not mathematically coupled.
Practical test for robot on KUKA linear unit/ROBROOT kinematic system
Applicable up to and including System Software 8.5:

If practical tests are required for the machine data, this test must be per-
formed if the robot and the KUKA linear unit (KL) are mathematically
coupled.
• Move the KL manually in Cartesian mode.
The practical test is passed if the TCP does not move at the same
time.
Applicable for System Software 8.6 or higher:
ried out if the robot is mounted on a mathematically coupled ROBROOT
kinematic system, e.g. on a KL.
• Move the axes of the ROBROOT kinematic system manually in Carte-
sian mode, individually and one after the other.
The practical test is passed if the TCP does not move at the same
time.
Practical test for couplable axes
ried out when axes are present that can be physically coupled and uncou-
pled, e.g. a servo gun.
1. Physically uncouple the couplable axis.
2. Move all the remaining axes individually.
The practical test is passed if it has been possible to move all the re-
maining axes.
3.8.4.2 Start-up mode
Description
The industrial robot can be set to Start-up mode via the smartHMI user in-
terface. In this mode, the manipulator can be moved in T1 without the ex-
ternal safeguards being put into operation.
The safety interface used affects “Start-up” mode:
Discrete safety interface
• System Software 8.2 or earlier:
Start-up mode is always possible if all input signals at the discrete
safety interface have the state “logic zero”. If this is not the case, the
robot controller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the
inputs there must also have the state “logic zero”.

• System Software 8.3 or higher:

Start-up mode is always possible. This also means that it is independ-
ent of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection
to a higher-level safety system exists or is established.
Effect
When the Start-up mode is activated, all outputs are automatically set to
the state “logic zero”.
If the robot controller has a peripheral contactor (US2), and if the safety
configuration specifies for this to switch in accordance with the motion en-
able, then the same also applies in Start-up mode. This means that if mo-
tion enable is present, the US2 voltage is switched on – even in Start-up
mode.
The maximum number of switching cycles of the peripheral contactors is
175 per day.
Hazards
Possible hazards and risks involved in using Start-up mode:
• A person walks into the manipulator’s danger zone.

• In a hazardous situation, a disabled external EMERGENCY STOP de-
vice is actuated and the manipulator is not shut down.
Additional measures for avoiding risks in Start-up mode:
• Cover disabled EMERGENCY STOP devices or attach a warning sign

indicating that the EMERGENCY STOP device is out of operation.
• If there is no safety fence, other measures must be taken to prevent
persons from entering the manipulator’s danger zone, e.g. use of
warning tape.
Use
Intended use of Start-up mode:

• Start-up in T1 mode when the external safeguards have not yet been
installed or put into operation. The danger zone must be delimited at
least by means of warning tape.
• Fault localization (periphery fault).
• Use of Start-up mode must be minimized as much as possible.
WARNING
Risk of fatal injury due to non-operational external safeguards
Use of Start-up mode disables all external safeguards. Death, severe in-
juries or damage to property may result.
• There must be no persons in the danger zone of the manipulator
while it is in Start-up mode.
Misuse
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. KUKA is not liable for any damage resulting from such misuse.

KR C4 compact
Safety
3.8.5 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
• Programming
• 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, tooling or external axes (optional) must never touch
or project beyond the safety fence.
• Workpieces, tooling and other objects must not become jammed as a
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 and programming are 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.

• There must be no other persons inside the safeguarded area. It is the
responsibility of the operator to ensure this.
3.8.6 Simulation
Simulation programs do not correspond exactly to reality. Robot programs

created in simulation programs must be tested in the system in Manual
Reduced Velocity mode (T1). It may be necessary to modify the pro-
gram.
3.8.7 Automatic mode
Automatic mode is only permissible in compliance with the following safety

measures:
• All safety equipment and safeguards are present and operational.

• There are no persons in the system.
• The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for
no apparent reason, the danger zone must not be entered until an EMER-
GENCY STOP has been triggered.
3.8.8 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.

KR C4 compact
Safety
DANGER
Danger to life and limb due to live parts
The robot system must be disconnected from the mains power supply
prior to work on live parts. It is not sufficient to trigger an EMERGENCY
STOP or safety stop, because parts remain live. Death or severe inju-
ries may result.
• Before commencing work on live parts, turn off the main switch and
secure it against being switched on again.
If the controller variant in question does not have a main switch
(e.g. KR C5 micro), turn off the device switch then disconnect the
power cable and secure it so it cannot be reconnected.
• Then check to ensure that the system is deenergized.
• Inform the individuals involved that the robot controller is switched
off. (e.g. by affixing a warning sign)
Faulty components must be replaced using new components with the

same article numbers or equivalent components approved by KUKA
Deutschland GmbH for this purpose.
Cleaning and preventive maintenance work is to be carried out in accord-
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
Voltages in excess of 50 V (up to 780 V) can be present in various com-
ponents for several minutes after the robot controller has been switched
off! To prevent life-threatening injuries, no work may be carried out on the
industrial robot in this time.
On robot controllers with transformers, the transformers must be discon-
nected before working on components in the robot controller.
Water and dust must be prevented from entering the robot controller.
Counterbalancing system
Some robot variants are equipped with a hydropneumatic, spring or gas

cylinder counterbalancing system.
• Counterbalancing system classified below category I: is subject to
the Pressure Equipment Directive but exempt from application of the
Pressure Equipment Directive according to Art. 4, para. 3 and there-
fore not CE marked.
• Counterbalancing system classified as category I or higher: is
subject to the Pressure Equipment Directive and CE marked as a
component (see rating plate of the counterbalancing system). The
pressure equipment is placed on the market in conjunction with partly
completed machinery. Conformity is expressed on the declaration of
incorporation according to the Machinery Directive.
The user must comply with the applicable national laws, regulations and
standards pertaining to pressure equipment.
• In Germany, the counterbalancing system is work equipment according
to the German Ordinance on Industrial Safety and Health (BetrSichV).
Inspection intervals in Germany in accordance with the Ordinance on

KR C4 compact
Industrial Safety and Health, Sections 14 and 15. Inspection by the

Safety
user before commissioning at the installation site.

• Inspection intervals in all other countries must be researched and ob-
served. As a rule, however, at least the maintenance intervals speci-
fied by KUKA must be observed. Shorter intervals are not permitted.
The following safety measures must be carried out when working on the
counterbalancing system:
• The assemblies supported by the counterbalancing systems must be
secured.
• Work on the counterbalancing systems must only be carried out by
qualified personnel.
Hazardous substances
The following safety measures must be carried out when handling hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.
• Clean skin and apply skin cream.
Use current safety data sheets

Knowledge of the safety data sheets of the substances and mixtures
used is a prerequisite for the safe use of KUKA products. Death,
injuries or damage to property may otherwise result.
• Request up-to-date safety data sheets from the manufacturers of
hazardous substances regularly.
3.8.9 Decommissioning, storage and disposal
The industrial robot must be decommissioned, stored and disposed of in

accordance with the applicable national laws, regulations and standards.
3.8.10 Safety measures for single point of control
Overview
If certain components are used on the industrial robot, safety measures

must be taken to ensure complete implementation of the principle of “sin-
gle point of control” (SPOC).
The relevant components are:
• Submit interpreter
• PLC
• OPC server
• Remote control tools
• Tools for configuration of bus systems with online functionality
• KUKA.RobotSensorInterface
• KUKA.DeviceConnector
(not KUKA.DeviceConnector pre-installed)
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, e.g. in the event of an EMERGENCY STOP.

KR C4 compact
Safety
Further safety measures for Single Point of Control
Depending on the specific application, further safety measures may be
required to ensure complete implementation of the principle of “single
point of control”. Failure to take this precaution into consideration may
result in death, injuries or damage to property.
• Check whether further safety measures are required; if so, imple-
ment them.
T1, T2
In modes T1 and T2, the components referred to above may only access
the industrial robot if the following signals have the following states:
Signal State required for SPOC
$USER_SAF TRUE
$SPOC_MOTION_ENABLE TRUE
Submit interpreter, PLC
If motions, (e.g. drives or grippers) are controlled with the submit interpret-
er or the PLC via the I/O system, and if they are not safeguarded by oth-
er means, then this control will take effect even in T1 and T2 modes or
while an EMERGENCY STOP is active.
If variables that affect the robot motion (e.g. override) are modified with
the submit interpreter or the PLC, this takes effect even in T1 and T2
modes or while an EMERGENCY STOP is active.
• In T1 and T2, the system variable $OV_PRO must not be written to
by the submit interpreter or the PLC.
OPC server, KUKA.DeviceConnector, remote control tools
These components can be used with write access to modify programs,

outputs or other parameters of the robot controller, without this being no-
ticed by any persons located inside the system.
Safety measure:
If these components are used, outputs that could cause a hazard must be
determined in a risk assessment. These outputs must be designed in such
a way that they cannot be set without being enabled. This can be done
using an external enabling device, for example.
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.
• WorkVisual from KUKA
• Tools from other manufacturers
Safety measure:
In the test modes, programs, outputs or other parameters of the robot
controller must not be modified using these components.


KR C4 compact
Technical data
4 Technical data
Basic data
Cabinet type 19" chassis

Color RAL 7016
Number of axes max. 6
Weight 33 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 200 V - 230 V AC, single-phase,
two-phase (with grounded neutral
(as symmetrical as possible) be-
tween the phases used
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 2 kVA, see rating plate
Thermal power dissipation max. 400 W
Mains-side fusing 2x 16 A slow-blowing (1 (2)x
phase; 1x neutral conductor (op-
tional))
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
With derating max. 3000 m above mean sea lev-
el (derating 5%/1000 m)

Technical data KR C4 compact
Overvoltage category II From 2000 m to 3000 m above

mean sea level
Overvoltage category III up to 2000 m above mean sea
level
Degree of fouling 2
NOTICE
Destruction of the batteries due to exhaustive discharge
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, recharge the batteries
every 9 months.
• If the storage temperature is between +20 °C and +30 °C, recharge
the batteries every 6 months.
Vibration resistance
During transpor- During continuous

Type of loading
tation operation
r.m.s. acceleration (sus- 0.37 g 0.1 g
tained oscillation)
Frequency range 4...120 Hz
(sustained oscillation)
Acceleration (shock in 10 g 2.5 g
X/Y/Z direction)
Waveform/duration (shock Half-sine/11 ms
in X/Y/Z direction)
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
Control PC
Main processor See shipping version

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

Dimensions approx. 24 cm x 29 cm x 5 cm
(width x height x depth)
Weight 1.1 kg
Protection rating IP54
(only with USB stick removed and
with USB connection closed with a
plug)
Interfaces USB

KR C4 compact
Technical data
Display Touch-sensitive color display
Resolution of 600 x 800 pixels
Display size 8.4"
KUKA smartPAD-2
Further information about the smartPAD-2 is contained in the operating

instructions of the smartPAD-2.
Cable lengths
For cable designations, standard lengths and optional lengths, please

refer to the operating instructions or assembly instructions of the manipu-
lator and/or the assembly and operating instructions for KR C4 external
cabling for robot controllers.
When using smartPAD cable extensions, only two extensions may be
used. An overall cable length of 50 m must not be exceeded.
The difference in the cable lengths between the individual channels of

the RDC box must not exceed 10 m.
4.1 Dimensions
The dimensions of the robot controller are indicated in the diagram

(>>> Fig. 4-1).
Fig. 4-1: Dimensions
1 Top view
2 Front view
3 Side view

4.2 Cabinet Interface Board, Small Robot
The power contacts must only be fed from a safely isolated PELV
power supply unit.
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
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.

KR C4 compact
Technical data
4.3 Dimensions of the smartPAD holder (optional)
The diagram (>>> Fig. 4-2) shows the dimensions and drilling locations
for mounting on the safety fence.
Fig. 4-2: Dimensions and drilling locations for smartPAD holder
4.4 Dimensions of handle brackets
Fig. 4-3: Dimensions of handle brackets
4.5 Plates and labels
Overview
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.

Designations
Fig. 4-4: Plates and labels
Item Description
1
Robot controller rating plate

2
Remove mains connector

Unplug mains connector before opening the housing.
3
Electric shock hazard

The operating instructions and safety regulations must be read
and understood before work is carried out on the robot control-
ler.
The plates may vary slightly from the examples illustrated above de-
pending on the specific cabinet type or as a result of updates.

KR C4 compact
Technical data
4.6 REACH duty to communicate information acc. to Art. 33
As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment and of the Council dated 18 December 2006 on the registration,
evaluation and authorization of chemicals (REACH Regulation) is in force.
Detailed REACH information can be found in the product information in
KUKA Xpert.


KR C4 compact
Planning
5 Planning
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.
Overview
Step Description Information

1 Electromagnetic compatibility (>>> 5.1 "Electromagnetic
(EMC) compatibility (EMC)"
Page 63)
2 Installation conditions for ro- (>>> 5.2 "Installation condi-
bot controller tions" Page 64)
3 Connection conditions (>>> 5.3 "Connection condi-
tions" Page 65)
4 PE equipotential bonding (>>> 5.4 "PE equipotential
bonding" Page 66)
5 Power supply connection (>>> 5.5 "Power supply con-
nection" Page 67)
6 Safety interface X11 (>>> 5.6 "Safety interface
X11" Page 67)
7 Ethernet safety interface X66 (>>> 5.7 "Safety functions
via Ethernet safety interface"
Page 75)
8 Mastering test (>>> 5.8 "Mastering test"
Page 85)
9 KUKA Extension Bus inter- (>>> 5.9 "X65 EtherCAT in-
face X65 terface" Page 85)
10 KUKA System Bus interface (>>> 5.10 "X69 KUKA Serv-
X69 ice Interface" Page 86)
11 Performance level (>>> 5.11 "Performance lev-
el" Page 87)
5.1 Electromagnetic compatibility (EMC)
Description
If connecting cables (e.g. field buses, etc.) are routed to the control PC
from outside, only shielded cables with an adequate degree of shielding
may be used.
The 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.

Planning KR C4 compact
5.2 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 55) must be observed. If the robot controller is to be installed
in a 19" rack, the depth must be at least 700 mm.The robot controller is
designed for use in the horizontal position. The robot controller can option-
ally be operated in the vertical position.
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 always be accessible to the cooling
air. Clearance of 70 mm on each side.
Fig. 5-1: Dimensions
Handle brackets
Fig. 5-2: Dimensions of handle brackets

KR C4 compact
Planning
CAUTION
Risk of injury and damage to property due to conductive dirt or
condensation
If the robot controller is operated in an environment with conductive dirt
or condensation, this can lead to uncontrolled electrical connections in-
side the robot controller. Injuries or damage to property may result.
• The robot controller may only be operated in environments without
conductive dirt.
• Avoid humidity and condensation.
CAUTION
Risk of injury and damage to property due to operation in non-ap-
proved environment
If the robot controller is operated in an environment with a higher de-
gree of fouling and possibly with formation of condensation, this can
lead to uncontrolled electrical connections inside the robot controller.
These ambient conditions correspond to degree of fouling 3 or 4.
Non-compliance can result in injury or damage to property.
• In the case of environments with heavy fouling, the robot controller
must be integrated into an appropriate protective enclosure.
• It must be ensured that the installation site is protected from con-
ductive fouling or condensation, e.g. through an appropriate housing
or cabinet with a protective rating of at least IP 54. The required
protective rating for the housing or cabinet must always be deter-
mined on the basis of the given ambient conditions and may be
higher than IP 54.
5.3 Connection conditions
Power supply connection
The robot controller may only be connected to grounded-neutral power

supply systems.
Rated supply voltage 200 V - 230 V AC, single-phase,
two-phase (with grounded neutral
(as symmetrical as possible) be-
tween the phases used
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 2 kVA, see rating plate
Thermal power dissipation max. 400 W
Mains-side fusing 2x 16 A slow-blowing (1 (2)x
phase; 1x neutral conductor (op-
tional))
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.
If use of a residual-current circuit-breaker (RCCB) is planned, KUKA

recommends the following: trip current difference 300 mA for controllers
up to and including WK35/2017 (see identification plate), and trip
current difference 30 mA per robot controller, universal-current sensitive,
selective, for controllers from WK36/2017 onwards.
Cable lengths
For cable designations, standard lengths and optional lengths, please

refer to the operating instructions or assembly instructions of the manipu-
lator and/or the assembly and operating instructions for KR C4 external
cabling for robot controllers.
When using smartPAD cable extensions, only two extensions may be
used. An overall cable length of 50 m must not be exceeded.
The difference in the cable lengths between the individual channels of

the RDC box must not exceed 10 m.
5.4 PE equipotential bonding
Description
The following cables must be connected before start-up:

• A 4 mm2 cable as equipotential bonding between the manipulator and
• An additional PE conductor between the central PE rail of the supply
cabinet and the PE connection of the robot controller. A cross section
of 4 mm2 is recommended.
Fig. 5-3: Equipotential bonding between the manipulator and the ro-
bot controller

KR C4 compact
Planning
1 Equipotential bonding connection on the manipulator
2 Equipotential bonding between the manipulator and the robot con-
troller
3 PE cable to the central PE rail of the supply cabinet
4 Equipotential bonding connections on the robot controller
5.5 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
• 200 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 16 A slow-blowing, type C (1 (2)x phase; 1x neutral conductor (op-

tional))
5.6 Safety interface X11
Description
EMERGENCY STOP devices must be connected via safety interface X11

or linked together by means of higher-level controllers (e.g. PLC).
Wiring
Take the following points into consideration when wiring safety interface
X11:
• System concept
• Safety concept
5.6.1 Contact diagram for connector X11
Description
The counterpart to interface X11 is a 50-contact D-Sub IP67 male multi-

point connector.

Fig. 5-4: Contact diagram, view from connection side
Outer diameter of cable: max. 14 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).
5.6.2 X11 safety interface
The X11 safety interface is wired internally to the CCU.
Connector pin allocation
Pin Description Function

1 Test output A Makes the pulsed voltage
3 available for the individual in-
(Test signal A)
terface inputs of channel A.
5
7
18
20
22
10 Test output B Makes the clocked voltage
12 available for the individual in-
(Test signal B)
terface inputs of channel B.
14
16
28
30
32
2 External E-STOP channel A E-STOP, dual-channel input,
max. 24 V. (>>> "CIB_SR in-
(Safe input 1)
puts" Page 58)
11 External E-STOP, channel B
Triggering of the E-STOP func-
(Safe input 1) tion in the robot controller.

KR C4 compact
Planning
4 Operator safety, channel A For dual-channel connection of
a safety gate locking mecha-
(Safe input 2)
nism, max. 24 V.
13 Operator safety, channel B (>>> "CIB_SR inputs"
(Safe input 2) Page 58)
As long as the signal is active,
the drives can be switched on.
Only effective in the AUTO-
MATIC modes.
6 Acknowledge operator safety, For connection of a dual-chan-
channel A nel input for acknowledging
operator safety with floating
(Safe input 3)
contacts. (>>> "CIB_SR in-
15 Acknowledge operator safety, puts" Page 58)
channel B
The response of the “Operator
(Safe input 3) safety acknowledgement” input
can be configured in the
KUKA system software.
After closing the safety gate
(operator safety), manipulator
motion can be enabled in the
automatic modes using an ac-
knowledge button outside the
safety fence. This function is
deactivated on delivery.
8 Safe operational stop, channel Activation of standstill monitor-
A ing
(Safe input 4) Stop 0 is initiated if the activa-
17 Safe operational stop, channel ted monitoring is violated.
B
(Safe input 4)
19 Safety stop 2, channel A Triggering of stop 2 and acti-
vation of standstill monitoring
(Safe input 5)
at standstill of all axes.
29 Safety stop 2, channel B
Stop 0 is initiated if the activa-
(Safe input 5) ted monitoring is violated.
21 External enabling 1 channel A For connection of an external
2-channel enabling switch 1
(Safe input 6)
with floating contacts.
31 External enabling 1 channel B
If no external enabling switch
(Safe input 6) 1 is connected, channel A pins
20/21 and channel B 30/31
must be jumpered. Only effec-
tive in TEST modes.
23 External enabling 2 channel A For connection of an external
2-channel enabling switch 2
(Safe input 7)
with floating contacts.
33 External enabling 2 channel B
If no external enabling switch
(Safe input 7) 2 is connected, channel A pins
22/23 and channel B 32/33
must be jumpered. Only effec-
tive in TEST modes.


34 Local E-STOP channel A Output, floating contacts from
35 internal E-STOP.
(>>> "CIB_SR outputs"
45 Local E-STOP channel B Page 58)
46 The contacts are closed if the
following conditions are met:
• E-STOP on smartPAD not

actuated
• Controller switched on and
operational
The contacts open if any con-
dition is not met.
36 Acknowledge operator safety, Output, floating contact for op-
37 channel A erator safety acknowledge-
ment, connection 1 and 2
47 Acknowledge operator safety,
channel B Output can be used to forward
48 the assured operator safety
(input BS = 1 and, if config-
ured, input QBS acknowl-
edged) to other robot control-
lers on the same safety fence.
38 Peri enabled, channel A Output, floating contact
39 (>>> "Signal “Peri enabled”"
49 Peri enabled, channel B Page 70)
50
Function of external axis enabling switch
• External enabling 1
Enabling switch must be pressed for jogging in T1 or T2. Input is
closed.
• External enabling 2
Enabling switch is not in the panic position. Input is closed.
• If a smartPAD is connected, its enabling switches and the external en-
abling are ANDed.
Function External ena- External ena-

Switch position
(only active for T1 and T2) bling 1 bling 2
Safety stop 1 (drives switched off Input open Input open No operational
when axis at standstill) state
Safety stop 2 (safe operational stop, Input open Input closed Not pressed
drives switched on)
Safety stop 1 (drives switched off Input closed Input open Panic position
when axis at standstill)
Axes enabled (axis jogging possible) Input closed Input closed Center position
Signal “Peri enabled”
The signal “Peri enabled” is set to 1 (active) if the following conditions are
met:
• Drives are switched on.

KR C4 compact
Planning
• Safety controller motion enable signal present.
• The message “Operator safety open” must not be active.
This message is only active in the modes T1 and T2.
“Peri enabled” in conjunction with the signal “Safe operational stop”
• In the case of activation of the signal “Safe operational stop” during
the motion:
‒ Error -> braking with Stop 0. “Peri enabled” eliminated.
• Activation of the signal “Safe operational stop” with the manipulator
stationary:
Release the brakes, switch drives to servo-control and monitor for re-
start. “Peri enabled” remains active.
‒ Signal “Motion enable” remains active.
‒ Signal “Peri enabled” remains active.
“Peri enabled” in conjunction with the signal “Safety stop 2”
• In the case of activation of the signal “Safety stop 2”:
‒ Stop 2 of the manipulator.
‒ Signal “Drive enable” remains active.
‒ Brakes remain released.
‒ Manipulator remains under servo-control.
‒ Monitoring for restart active.
‒ Signal “Motion enable” is deactivated.
‒ Signal “Peri enabled” is deactivated.
5.6.3 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. 5-5: Wiring example: EMERGENCY STOP
Safety gate
A dual-channel acknowledge button must be installed outside the physical

safeguard. The system integrator must ensure that closing the safety gate
inadvertently does not directly set the signal for operator safety. After the
safety gate has closed, the signal for operator safety must only be con-
firmed by an external device, e.g. an acknowledge button, that can only
be accessed from outside the danger zone. The closing of the safety gate
must be confirmed by pressing the acknowledge button before the indus-
trial robot can be started again in Automatic mode.
WARNING
The safety gate on the robot controller must be integrated into the safe-
guard circuit of the system by the system integrator.
Failure to do this may result in death, severe injuries or considerable
damage to property.

KR C4 compact
Planning
Fig. 5-6: Wiring example: Operator safety with safety gate
5.6.4 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. 5-7: Connection schematic for safe input
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. 5-8: Switch-off pulse diagram, test outputs
t1 Switch-off pulse length

t2 Switch-off period per channel (106 ms)
t3 Offset between switch-off pulses of both channels
(53 ms)
TA/A Test output channel A
TA/B Test output channel B
SIN_X_A Input X, channel A
SIN_X_B Input X, channel B

KR C4 compact
Planning
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. 5-9: 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).
5.7 Safety functions via Ethernet safety interface
Description
The exchange of safety-relevant signals between the controller and the

system is carried out via the Ethernet safety interface (e.g. PROFIsafe or
CIP Safety). The assignment of the input and output states within the
Ethernet safety interface protocol are listed below. In addition, non-safety-
oriented information from the safety controller is sent to the non-safe sec-
tion of the higher-level controller for the purpose of diagnosis and control.
Reserved bits
Reserved safety-oriented inputs can be pre-assigned by a PLC with the

values 0 or 1. In both cases, the manipulator will move. If a safety func-
tion is assigned to a reserved input (e.g. in the case of a software update)
and if this input is preset with the value 0, then the manipulator either
does not move or comes unexpectedly to a standstill.

KUKA recommends pre-assignment of the reserved inputs with 1. If a

reserved input has a new safety function assigned to it, and the input is
not used by the customer’s PLC, the safety function is not activated.
This prevents the safety controller from unexpectedly stopping the ma-
nipulator.
Input byte 0
Bit Signal Description

0 RES Reserved 1
The value 1 must be assigned to the input.
1 NHE Input for external Emergency Stop
0 = external E-STOP is active
1 = external E-STOP is not active
2 BS Operator safety
0 = operator safety is not active, e.g. safety gate
open
1 = operator safety is active
3 QBS Acknowledgement of operator safety
Precondition for acknowledgment of operator safety
is the signal "Operator safety active" set in the BS
bit.
Note: If the “BS” signal is acknowledged by the
system, this must be specified under Hardware op-
tions in the safety configuration. Information is con-
tained in the Operating and Programming Instruc-
tions for System Integrators.
0 = operator safety has not been acknowledged
Edge 0 ->1 = operator safety has been acknowl-
edged
4 SHS1 Safety STOP 1 (all axes)
• FF (motion enable) is set to 0.

• Voltage US2 is switched off.
• AF (drives enable) is set to 0 after 1.5 s.
Cancelation of this function does not require ac-
knowledgement.
This function is not permissible for the EMERGEN-
CY STOP function.
0 = safety stop is active
1 = safety stop is not active

KR C4 compact
Planning
5 SHS2 Safety STOP 2 (all axes)
• FF (motion enable) is set to 0.

• Voltage US2 is switched off.
knowledgement.
CY STOP function.
0 = safety stop is active
1 = safety stop is not active
6 RES -
7 RES -
Input byte 1

0 US2 Supply voltage US2 (signal for switching the second
supply voltage, US2, without battery backup)
If this output is not used, it should be set to 0.
0 = switch off US2
1 = switch on US2
Note: Whether and how input US2 is used must be
specified under Hardware options in the safety
configuration. Information is contained in the Oper-
ating and Programming Instructions for System Inte-
grators.
1 SBH Safe operational stop (all axes)
Prerequisite: All axes are stationary
knowledgement.
CY STOP function.
0 = safe operational stop is active.
1 = safe operational stop is not active.
2 RES Reserved 11
3 RES Reserved 12
4 RES Reserved 13
5 RES Reserved 14
6 RES Reserved 15


7 SPA System Powerdown Acknowledge
The system confirms that it has received the power-
down signal. A second after the “SP” (System Pow-
erdown) signal has been set by the controller, the
requested action is executed, without the need for
confirmation from the PLC, and the controller shuts
down.
0 = confirmation is not active
1 = confirmation is active
Output byte 0

0 NHL Local E-STOP (local E-STOP triggered)
0 = local E-STOP is active
1 = local E-STOP is not active
1 AF Drives enable (the internal safety controller of the
robot controller has enabled the drives so that they
can be switched on)
0 = drives enable is not active (the robot controller
must switch the drives off)
1 = drives enable is active (the robot controller
must switch the drives to servo-control)
2 FF Motion enable (the internal safety controller of the
robot controller has enabled robot motions)
0 = motion enable is not active (the robot controller
must stop the current motion)
1 = motion enable is active (the robot controller
may trigger a motion)
3 ZS The signal ZS (enabling) is set to 1 (active) if the
• One of the enabling switches on the smartPAD

is in the center position (enabling signal has
been issued).
• T1 or T2 mode
• External enabling signal has been issued (signal
ZSE1/ZSE2).
• Robot can be moved (no external
EMERGENCY STOP, safety stop, etc.).
4 PE The signal “Peri enabled” is set to 1 (active) if the
• Drives are switched on.

• Safety controller motion enable signal present.
• The message “Operator safety open” must not
be active.

KR C4 compact
Planning
5 AUT The manipulator is in AUT or AUT EXT mode.
0 = AUT or AUT EXT mode is not active
1 = AUT or AUT EXT mode is active
6 T1 The manipulator is in Manual Reduced Velocity
mode.
0 = T1 mode is not active
1 = T1 mode is active
7 T2 The manipulator is in Manual High Velocity mode.
0 = T2 mode is not active
1 = T2 mode is active
Output byte 1

0 NHE External E-STOP has been triggered.
0 = external E-STOP is active
1 = external E-STOP is not active
1 BSQ Operator safety acknowledged
0 = operator safety is not assured
1 = operator safety is assured (input BS = 1 and,
if configured, input QBS acknowledged)
2 SHS1 Signal only available up to System Software 8.4
Safety STOP 1 (all axes)
0 = safety STOP 1 is not active
1 = safety STOP 1 is active (safe state reached)
SHS1EXT Signal available for System Software 8.5 or higher
(replaces SHS1)
External safety STOP 1 (all axes)
0 = external safety STOP 1 is not active
1 = external safety STOP 1 is active (input SHS1
= 0, safe state reached)
3 SHS2 Signal only available up to System Software 8.4
Safety STOP 2 (all axes)
0 = safety STOP 2 is not active
1 = safety STOP 2 is active (safe state reached)
SHS2EXT Signal available for System Software 8.5 or higher
(replaces SHS2)
External safety STOP 2 (all axes)
0 = external safety STOP 2 is not active
1 = external safety STOP 2 is active (input SHS2
= 0, safe state reached)
4 RES Reserved 13
5 RES Reserved 14


6 PSA Safety interface active
Precondition: an Ethernet interface must be instal-
led on the controller, e.g. PROFINET or
Ethernet/IP
0 = safety interface is not active
1 = safety interface is active
7 SP System Powerdown (controller will be shut down)
One second after the SP signal has been set, the
PSA output is reset by the robot controller, without
confirmation from the PLC, and the controller is
shut down.
0 = controller on safety interface is active.
1 = controller will be shut down
5.7.1 Schematic circuit diagram for enabling switches
Description
An external enabling switch can be connected to the higher-level safety

controller. The signals (ZSE make contact and External panic break con-
tact) must be correctly linked to the Ethernet safety interface signals in the
safety controller. The resulting Ethernet safety interface signals must then
be routed to the PROFIsafe of the KR C4. The response to the external
enabling switch is then identical to that for a discretely connected X11.
Signals
Fig. 5-10: Schematic circuit diagram of external enabling switch
• Enabling switch center position (make contact closed (1) = enabled)

OR AUT at SHS2
• Panic (break contact open (0) = panic position) = AND not AUT at
SHS1
5.7.2 SafeOperation via Ethernet safety interface (optional)
Description
The components of the industrial robot move within the limits that have
been configured and activated. The actual positions are continuously cal-
culated and monitored against the safety parameters that have been set.
The safety controller monitors the industrial robot by means of the safety
parameters that have been set. If a component of the industrial robot vio-
lates a monitoring limit or a safety parameter, the manipulator and

KR C4 compact
external axes (optional) are stopped. The Ethernet safety interface can be
Planning
used, for example, to signal a violation of safety monitoring functions.
In the case of the KR C4 compact or KR C4 compact slimline robot con-
troller, safety options such as SafeOperation are only available via the
Ethernet safety interface from KSS/VSS 8.3 onwards.
Reserved bits
Reserved safety-oriented inputs can be pre-assigned by a PLC with the

values 0 or 1. In both cases, the manipulator will move. If a safety func-
tion is assigned to a reserved input (e.g. in the case of a software update)
and if this input is preset with the value 0, then the manipulator either
does not move or comes unexpectedly to a standstill.
KUKA recommends pre-assignment of the reserved inputs with 1. If a
reserved input has a new safety function assigned to it, and the input is
not used by the customer’s PLC, the safety function is not activated.
This prevents the safety controller from unexpectedly stopping the ma-
nipulator.
Input byte 2

0 JR Mastering test (input for the reference switch
of the mastering test)
0 = reference switch is active (actuated).
1 = reference switch is not active (not actu-
ated).
1 VRED Reduced axis-specific and Cartesian velocity
(activation of reduced velocity monitoring)
0 = reduced velocity monitoring is active.
1 = reduced velocity monitoring is not active.
2 … 7 SBH1 … 6 Safe operational stop for axis group 1 ... 6
Assignment: Bit 2 = axis group 1 … bit 7 =
axis group 6
Signal for safe operational stop. The function
does not trigger a stop, it only activates the
safe standstill monitoring. Cancelation of this
function does not require acknowledgement.
Input byte 3

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

Input byte 4

0 … 7 UER1 … 8 Monitoring spaces 1 … 8
Assignment: Bit 0 = monitoring space 1 … bit
7 = monitoring space 8
0 = monitoring space is active.
1 = monitoring space is not active.
Input byte 5

0 … 7 UER9 … 16 Monitoring spaces 9 … 16
Assignment: Bit 0 = monitoring space 9 … bit
7 = monitoring space 16
0 = monitoring space is active.
1 = monitoring space is not active.
Input byte 6

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

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

0 SO Activation status of the safety option
0 = safety option is not active.
1 = safety option is active
1 RR Robot referenced
Mastering test display
0 = mastering is not referenced.
1 = mastering test performed successfully.

KR C4 compact
Planning
2 JF Mastering error
The space monitoring is deactivated if at least
one axis is not mastered.
0 = mastering error. Space monitoring has
been deactivated.
1 = no error.
3 VRED Reduced axis-specific and Cartesian velocity
(activation status of reduced velocity monitor-
ing)
0 = reduced velocity monitoring is not active.
1 = reduced velocity monitoring is active.
4 … 7 SBH1 ... 4 Activation status of safe operational stop for
axis group 1 ... 4
axis group 4
Output byte 3

0 … 1 SBH5 … 6 Activation status of safe operational stop for
axis group 5 ... 6
axis group 6
2 SOS Safe Operation Stop
0 = a safety function has triggered a stop.
The output remains in the “0” state for at least
200 ms.
1 = none of the safety functions has triggered
a stop.
Note: The output SOS is available in System
Software 8.3 or higher. In System Software
8.2 or lower, bit 2 is a spare bit.
3 … 7 RES Reserved 28 ... 32

Output byte 4

0 … 7 MR1 ... 8 Alarm space 1 … 8
Assignment: Bit 0 = alarm space 1 (associ-
ated monitoring space 1) … bit 7 = alarm
space 8 (associated monitoring space 8)
0 = monitoring space is violated.
1 = monitoring space is not violated.
Note: An inactive monitoring space is consid-
ered to be violated by default, i.e. in this case
the associated safety-oriented output MRx has
the state “0”.
Output byte 5

0 … 7 MR9 ... 16 Alarm space 9 … 16
Assignment: Bit 0 = alarm space 9 (associ-
ated monitoring space 9) … bit 7 = alarm
space 16 (associated monitoring space 16)
0 = monitoring space is violated.
1 = monitoring space is not violated.
Note: An inactive monitoring space is consid-
ered to be violated by default, i.e. in this case
the associated safety-oriented output MRx has
the state “0”.
Output byte 6

0 … 7 RES Reserved 49 ... 56
Output byte 7

0 … 7 RES Reserved 57 ... 64
5.7.3 X66 Ethernet interface (RJ45)
Description
Interface X66 can be used for connecting an external computer to the KU-
KA Line Interface for the purpose of installation, programming, debugging
and diagnosis.
Necessary equipment
• Connector RJ45
• Recommended connecting cable: Ethernet-compatible, min. category
CAT 5e
• Maximum cable cross-section: AWG22

KR C4 compact
Planning
Pin assignment
Fig. 5-11: Pin assignment
10BASE-T, 100BASE-TX allo-

Pin 1000BASE-TX allocation
cation
1 RX+ BI_DB+
2 RX- BI_DB-
3 TX+ BI_DA+
4 - BI_DD+
5 - BI_DD-
6 TX- BI_DA-
7 - BI_DC+
8 - BI_DC-
5.8 Mastering test
For the mastering test, a reference switch must be connected to the safe-
ty PLC and activated via PROFIsafe or CIP Safety. The safety PLC must
evaluate the reference switch and set the input “Mastering test” according-
ly.
5.9 X65 EtherCAT interface
Description
EtherCAT slaves outside the robot controller are connected via interface
X65. The EtherCAT line is routed out of the robot controller.
Interface X65 can be wired internally to the CCU, either directly or via a
bus coupler.
The EtherCAT devices must be configured with WorkVisual.
Necessary equipment
• Connector, Data 3A RJ45

• Cable clamping range: Ø9 ... Ø13 mm

• Recommended connecting cable: ethernet-compatible, min. category
CAT 5
Pin Description
1 TFPO_P
2 TFPO_N
3 TFPI_P
6 TFPI_I
- PE
5.10 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

KR C4 compact
Planning
• Recommended connecting cable: Ethernet-compatible, min. category

CAT 5
Connector pin allocation X69
Pin Description
1 TFPO_P
2 TFPO_N
3 TFPI_P
6 TFPI_I
- PE
5.11 Performance level
The safety functions of the robot controller conform to Category 3 and

Performance Level d according to EN ISO 13849-1.
5.11.1 PFH values of the safety functions
The safety values are based on a service life of 20 years.

The PFH value classification of the controller is only valid if the EMER-
GENCY STOP device and the enabling switches on the smartPAD are
tested at least once every 12 months.
When evaluating system safety functions, it must be remembered that the
PFH values for a combination of multiple controllers may have to be taken
into consideration more than once. This is the case for RoboTeam sys-
tems or higher-level hazard areas. The PFH value determined for the
safety function at system level must not exceed the limit for PL d.
The PFH values relate to the specific safety functions of the different con-
troller variants.
Safety function groups:
• Standard safety functions

‒ Operating mode selection
‒ Operator safety

‒EMERGENCY STOP device

‒Enabling device
‒External safe operational stop
‒External safety stop 1
‒External safety stop 2
‒Velocity monitoring in T1
‒Control of the peripheral contactor (not available for all robot con-
troller variants)
• Safety functions of KUKA Safe Operation Technology (optional)
‒ Monitoring of axis spaces
‒ Monitoring of Cartesian spaces
‒ Monitoring of axis velocity
‒ Monitoring of Cartesian velocity
‒ Monitoring of axis acceleration
‒ Safe operational stop
‒ Tool monitoring
Overview of controller variant PFH values:
Robot controller variant PFH value
KR C4; KR C4 CK < 1 x 10-7
KR C4 midsize; KR C4 midsize CK < 1 x 10-7
KR C4 extended; KR C4 extended CK < 1 x 10-7
KR C4 NA; KR C4 CK NA < 1 x 10-7
KR C4 NA variant: TTE1 < 1 x 10-7
KR C4 NA extended; KR C4 CK NA extended < 1 x 10-7
KR C4 variant: TBM1 < 1 x 10-7
KR C4 variants: TDA1; TDA2; TDA3; TDA4 < 1 x 10-7
KR C4 smallsize-2 variants: TDA4 < 1 x 10-7
KR C4 variants: TFO1; TFO2 < 2 x 10-7
KR C4 variants: TRE1; TRE2 < 1.8 x 10-7
KR C4 variant: TRE3 < 1 x 10-7
KR C4 variants: TVO1; TVO2; TVO3 < 1 x 10-7
VKR C4 variants: TVW1; TVW2; TVW3; TVW4, TVW5, < 1 x 10-7
TVW6, TVW7, TVW8, TVW0
VKR C4 smallsize-2 variants: TVW1; TVW3, TVW7, < 1 x 10-7
TVW8, TVW0
VKR C4 Retrofit KR C1 < 2.7 x 10-7
VKR C4 Retrofit KR C2 < 1 x 10-7
KR C4 Panel Mounted < 1 x 10-7
KR C4 compact < 1 x 10-7
KR C4 compact slimline < 1 x 10-7
KR C4 smallsize < 1 x 10-7
KR C4 smallsize-2 < 1 x 10-7
KR C4 smallsize-2 with KR C4 smallsize drive box < 1 x 10-7

KR C4 compact
Planning
For controller variants that are not listed here, please contact KUKA
Deutschland GmbH.


KR C4 compact
Transportation
6 Transportation
6.1 Transporting the robot controller
Preconditions
• The housing of the robot controller must be closed.

• No cables may be connected to the robot controller.
• The robot controller must be transported in a horizontal position.
Procedure
• Transport the robot controller using a pallet truck or a fork lift truck.
The robot controller must be laid on a pallet.
Fig. 6-1: Transportation by fork lift truck
If the robot controller is installed in an electrical enclosure during trans-

portation, this may result in vibrations (oscillations). Such vibrations can
cause contact problems on the PC plug-in cards.

Transportation KR C4 compact

KR C4 compact
Start-up and recommissioning

7 Start-up and recommissioning
7.1 Start-up overview
This is an overview of the most important steps during start-up. The

precise sequence depends on the application, the manipulator type, the
technology packages used and other customer-specific 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

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

4 Carry out a visual inspection of the robot con- -
troller.
5 Make sure that no condensation has formed -
in the robot controller.
6 Install the robot controller. (>>> 7.2 "Installing the robot con-
troller" Page 94)
7 Connect the equipotential bonding between (>>> 7.3 "Connecting the equipo-
the manipulator and the robot controller. tential bonding (PE)" Page 94)
8 Connect the connecting cables. (>>> 7.4 "Connecting the con-
necting cables" Page 95)
9 Plug in the KUKA smartPAD. (>>> 7.5 "Plugging in the KUKA
smartPAD" Page 96)
10 Connect the robot controller to the power (>>> 7.7 "Connecting the robot
supply. controller to the power supply"
Page 97)
11 Reverse the battery discharge protection (>>> 7.6 "Reversing the battery
measures. discharge protection measures"
Page 97)
12 Configure and connect safety interface X11. (>>> 7.8 "Configuring and con-
necting connector X11" Page 98)
13 Switch on the robot controller. (>>> 7.9 "Switching on the robot
controller" Page 99)
14 Check the safety equipment. Detailed information is contained
in the operating and assembly in-
structions for the robot controller,
in the “Safety” chapter.
15 Configure the inputs/outputs between the ro- Detailed information can be found
bot controller and the periphery. in the field bus documentation.

Start-up and recommissioning KR C4 compact
Software

16 Check the machine data. Detailed information is contained
17 Master the manipulator without a load. in the operating and programming
instructions.
18 Mount the tool and master the manipulator
with a load.
19 Check the software limit switches and adapt
them if required.
20 Calibrate the tool.
In the case of a fixed tool: calibrate external
TCP.
21 Enter the load data.
22 Calibrate the base (optional).
In the case of a fixed tool: calibrate
workpiece (optional).
23 If the manipulator is to be controlled by a Detailed information is contained
host computer or PLC: configure the Automat- in the Operating and Program-
ic External interface. ming Instructions for System Inte-
grators.
7.2 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.
7.3 Connecting the equipotential bonding (PE)
Procedure
1. Route and connect a 4 mm2 cable as equipotential bonding between

the manipulator and the robot controller at the installation site.
(>>> 5.4 "PE equipotential bonding" Page 66)
Route the equipotential bonding by the shortest route from the robot
controller to the manipulator.
2. Ground the robot controller at the installation site.
3. Carry out a ground conductor check for the entire robot system in ac-
cordance with EN 60204-1.

KR C4 compact

7.4 Connecting the connecting cables
Overview
A cable set is supplied with the robot system. The basic version consists
of:
• Motor cable, data cable
• Device connection cable
The following cables may be provided for additional applications:
• Peripheral cables
Procedure
1. Connect motor connector X20 to the drive box.

2. Connect data cable connector X21 to the control box.
7.4.1 Motor connector X20
Description
The motors and brakes of the robot axes are connected to the robot con-
troller via motor connector X20.
Necessary equipment
• Harting Han-Yellock monoblock, size 30
Fig. 7-1: Contact diagram, view from contact side
Motor connector X20
Pin Description
1 Motor M1 U1
6 Motor M1 V1
11 Motor M1 W1
2 Motor M2 U1
7 Motor M2 V1
12 Motor M2 W1
3 Motor M3 U1
8 Motor M3 V1
13 Motor M3 W1
4 Motor M4 U1
9 Motor M4 V1
14 Motor M4 W1
5 Motor M5 U1

Pin Description
10 Motor M5 V1
15 Motor M5 W1
21 Motor M6 U1
22 Motor M6 V1
23 Motor M6 W1
18 Brake, axes 1-3, 24 V
24 Brake, axes 1-3, GND
19 Brake, axes 4-6, 24 V
25 Brake, axes 4-6, GND
20 PE
7.4.2 X21 Data cable
Pin Description
1 +24 V PS1
2 GND
5 +24V network
6 GND
9 TPFO_P
10 TPFI_P
11 TPFO_N
12 TPFI_N
7.5 Plugging in the KUKA smartPAD
Procedure
• Plug the KUKA smartPAD to X19 on the robot controller.
WARNING
Risk of fatal injury due to non-operational EMERGENCY STOP de-
vice
If the smartPAD is disconnected, the system can no longer be switched
off by means of the EMERGENCY STOP device on the smartPAD.
Measures must be taken to prevent operational and non-operational
EMERGENCY STOP devices from being mixed up.
Death, injuries or damage to property may result.
• Connect an external EMERGENCY STOP to the robot controller.
Pin Description
11 TD+
12 TD-
2 RD+

KR C4 compact

Pin Description
3 RD-
8 smartPAD plugged in (A) 0 V
9 smartPAD plugged in (B) 24 V
5 24 V PS2
6 GND
7.6 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.
Fig. 7-2: Battery discharge protection X305
1 Connector X305 on the CCU_SR
7.7 Connecting the robot controller to the power supply
7.7.1 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.
7.7.2 Connecting the robot controller to the power supply without a mains
connector
Precondition

• 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 55)
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. 7-3).
• 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. 7-3: Power supply connection
7.8 Configuring and connecting connector X11
Precondition
Procedure
1. Configure connector X11 in accordance with the system and safety

concepts. (>>> 5.6.2 "X11 safety interface" Page 68)
2. Connect interface connector X11 to the robot controller.

KR C4 compact

NOTICE
Damage to property due to plugging or unplugging of live connec-
tors
Connector XG11 may only be plugged in or unplugged when the robot
controller is switched off. If connector XG11 is plugged in or unplugged
when energized, damage to property may occur.
• Switch off the robot controller.
7.9 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 EMERGENCY STOP device on the smartPAD.

2. Turn on the main switch or device 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.


KR C4 compact
Operation
8 Operation
8.1 KUKA smartPAD teach pendant
The smartPAD is the teach pendant for the industrial robot. The smartPAD
has all the operator control and display functions required for operating
and programming the industrial robot.
Two models exist:
• smartPAD
• smartPAD-2
In this documentation, the designation “KUKA smartPAD” or “smartPAD”
refers to both models unless an explicit distinction is made.
8.1.1 smartPAD
8.1.1.1 Front of smartPAD
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.
Fig. 8-1: Front of smartPAD

Operation KR C4 compact
Item Description
1 Button for disconnecting the smartPAD
(>>> 8.1.3 "Disconnecting and connecting the smartPAD" Page 104)
2 Mode selector switch: the switch may be one of the following variants:
• With key
It is only possible to change operating mode if the key is inserted.
• Without key
The mode selector switch is used to call the connection manager. The connection
manager is used to change the operating mode.
3 EMERGENCY STOP device: Stops the robot in hazardous situations. The EMER-
GENCY STOP device locks itself in place when it is pressed.
4 Space Mouse: For moving the robot manually
5 Jog keys: For moving the robot manually
6 Key for setting the program override
7 Key for setting the jog override
8 Main menu key: Shows the menu items on the smartHMI. It can also be used for cre-
ating screenshots.
9 Status buttons: The status keys are used primarily for setting parameters in option
packages. Their exact function depends on the option packages installed.
10 Start key: The Start key is used to start a program.
11 Start backwards key: The Start backwards key is used to start a program backwards.
The program is executed step by step.
12 STOP key: The STOP key is used to stop a program that is running.
13 Keyboard key:
Displays the keyboard. It is generally not necessary to press this key to display the
keyboard, as the smartHMI detects when keyboard input is required and displays the
keyboard automatically.

KR C4 compact
8.1.1.2 Rear of smartPAD
Operation
Fig. 8-2: Rear of smartPAD
1 Enabling switch 4 USB connection

2 Start key (green) 5 Enabling switch
3 Enabling switch 6 Identification plate
Item Description
1 Enabling switch
The enabling switches have 3 positions:
• Not pressed
• Center position
• Fully pressed (panic position)
In the test modes, the manipulator can only be moved if at least one of the enabling
switches is held in the center position.
In the Automatic and Automatic External modes, the enabling switches have no func-
tion.
2 Start key (green): the Start key is used to start a program.
3 Enabling switch
4 USB connection: it is used, for example, for archiving and restoring data.
Only for FAT32-formatted USB sticks.
5 Enabling switch

Item Description
6 Identification plate
8.1.2 smartPAD-2
KUKA smartPAD-2
Further information about the smartPAD-2 is contained in the operating

instructions of the smartPAD-2.
8.1.3 Disconnecting and connecting the smartPAD
Description
The information is applicable for both the smartPAD and the smartPAD-2.
WARNING
vice
If the smartPAD is disconnected, the system can no longer be switched
off by means of the EMERGENCY STOP device on the smartPAD.
Measures must be taken to prevent operational and non-operational
EMERGENCY STOP devices from being mixed up.
Death, injuries or damage to property may result.
• Connect an external EMERGENCY STOP to the robot controller.
The “smartPAD” and “smartPAD-2” models are compatible with one an-
other, i.e. if one model has been disconnected, then the other model
can then be plugged in.
It must be ensured that the Space Mouse (6D mouse) is not deflected
when connecting the smartPAD to a controller that is runnning or when
switching on the controller. Otherwise the mouse will not function cor-
rectly.
Procedure
Disconnection:
The smartPAD can also be disconnected while the robot controller is run-
ning.
1. Press the disconnect button on the smartPAD.
A message and a counter are displayed on the smartHMI. The
counter runs for 25 s. During this time, the smartPAD can be discon-
nected from the robot controller.
If the counter expires without the smartPAD having been
disconnected, this has no effect. The disconnect button can be press-
ed again at any time to display the counter again.
2. Disconnect the smartPAD from the robot controller.
If the smartPAD is disconnected without the counter running, this trig-

gers an EMERGENCY STOP. The EMERGENCY STOP can only be
canceled by plugging the smartPAD back in.
Connection:
A smartPAD can be connected at any time.

KR C4 compact
Operation
1. Connect the smartPAD to the robot controller.
• The EMERGENCY STOP and enabling switches are operational
again 30 s after connection.
• The smartHMI is automatically displayed again. (This may take
longer than 30 s.)
• The connected smartPAD assumes the current operating mode of
The current operating mode is not, in all cases, the same as that
before the smartPAD was disconnected: if the robot controller is part
of a RoboTeam, the operating mode may have been changed after
disconnection, e.g. by the master.
2. Check the functions. The following checks must be performed:

• Function test of EMERGENCY STOP
• Function test for the enabling switches
• Check whether the smartHMI is displayed again. (This may take
longer than 30 s.)
WARNING
vice
If a non-operational smartPAD remains connected, there is the danger
that the user will attempt to activate a non-operational EMERGENCY
STOP. Death, injuries or damage to property may result.
• Disconnect a non-operational smartPAD and remove it from the sys-
tem immediately.


KR C4 compact
Maintenance
9 Maintenance
Description
Maintenance work must be performed at the specified maintenance inter-

vals after commissioning at the customer’s plant.
9.1 Maintenance symbols
Maintenance symbols
The overview may contain maintenance symbols that are not relevant
for the maintenance work on this product. The maintenance illustrations
provide an overview of the relevant maintenance work.
Oil change
Lubricate with grease gun
Lubricate with brush
Lubricate with spray grease
Tighten screw/nut
Check component, visual inspection
Clean component
Exchange battery
Exchange component
Check toothed belt tension
Precondition
• The robot controller must be switched off and secured to prevent un-
authorized persons from switching it on again.
• Power supply lead disconnected.
• Wait 5 minutes until the intermediate circuit has discharged.

Maintenance KR C4 compact
Work safety
WARNING
Danger to life and limb due to high intermediate circuit voltages
Some components may remain energized (50...300 V) up to 5 minutes
after the robot controller has been switched off. Death, severe injuries
or damage to property may result.
• After switching off, wait at least 5 minutes until the intermediate cir-
cuit has discharged.
The following components may remain energized for up to 5 mi-
nutes:
‒ KPP_SR
‒ KSP_SR
‒ Connections for motor connector and connected motor cables
‒ Intermediate circuit connecting cables
NOTICE
Damage to or destruction of components due to electrostatic dis-
charge (ESD)
Electrostatic discharge during installation or removal work can result in
destruction or partial damage to electronic components.
• Observe the ESD guidelines.
Fig. 9-1: Maintenance diagram

KR C4 compact
Maintenance
Interval Item Activity
6 months 4 Check the utilized relay outputs of the CCU_SR for
correct functioning. (>>> 9.2 "Checking CCU_SR
relay outputs" Page 109)
1 year - Cyclical function test of operator safety and all
EMERGENCY STOP devices (e.g. smartPAD, ex-
ternal EMERGENCY STOP devices, etc.)
- Perform function test of all enabling switches on
the smartPAD.
- Function test of external enabling devices
1 year at 1/5 Depending on installation conditions and degree of
the latest fouling, clean the protective grille and fan with a
brush.
5 years 2 Exchange the motherboard battery. (>>> 10.3 "Ex-
changing the motherboard battery" Page 119)
5 years 1 Exchange the control box fans. (>>> 10.12 "Ex-
(with 3-shift changing the control box fans" Page 154)
operation) 5 Exchange the drive box fans. (>>> 10.13 "Ex-
changing the drive box fans" Page 158)
As indica- 3 Exchange the batteries. (>>> 10.7 "Exchanging the
ted by the battery" Page 135)
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.
9.2 Checking CCU_SR relay outputs
Activity
Check the function of the output Local EMERGENCY STOP.
Procedure
• Press the local EMERGENCY STOP device.
Activity
Check the function of the output Operator safety acknowledged.
Procedure
1. Set operating mode to Automatic or Automatic External.

2. Open operator safety (safeguard).
Activity
Check the function of the output Switch on periphery.

Procedure
1. Set operating mode to Automatic or Automatic External.

2. Open operator safety (safeguard).
3. Release enabling switch in “T1” or “T2” mode.
If no error message is displayed, the relay outputs are OK.
9.3 Cleaning the robot controller
Precondition
• Wait 5 minutes until the intermediate circuit has discharged.
Work safety
WARNING
Danger to life and limb due to high intermediate circuit voltages
Some components may remain energized (50...300 V) up to 5 minutes
after the robot controller has been switched off. Death, severe injuries
or damage to property may result.
• After switching off, wait at least 5 minutes until the intermediate cir-
cuit has discharged.
The following components may remain energized for up to 5 mi-
nutes:
‒ KPP_SR
‒ KSP_SR
‒ Connections for motor connector and connected motor cables
‒ Intermediate circuit connecting cables
WARNING
Risk of fatal injury from voltage
The device switch on the robot controller does not have a grid isolation
function. Failure to take this into consideration may result in severe inju-
ries or even death.
• Before undertaking work on the robot controller, the power cable on
the robot controller must be disconnected.
• Store the disconnected power cable out of sight and reach of per-
sonnel working on the robot controller.
• Use a sign to inform the individuals involved that the robot controller
is switched off (e.g. by affixing a warning sign).
NOTICE
charge (ESD)
Work regulations
• The manufacturer’s instructions must be observed when using clean-

ing agents for cleaning work.

KR C4 compact
Maintenance
• 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.


KR C4 compact
Repair
10 Repair
10.1 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 held by KUKA Deutschland GmbH.
Repairs within modules may only be carried out by specially trained KUKA
Deutschland GmbH personnel.
Procurement of spare parts
The article numbers of the spare parts are listed in the spare parts cata-
log.
KUKA Deutschland GmbH supplies the following types of spare parts for
repairs to the robot controller:
• New parts
Once the new part has been installed, the part that has been removed
can be disposed of.
• Exchange parts
Once the exchange part has been installed, the part that has been re-
moved is returned to KUKA Deutschland GmbH.
A “Robot Repair Card” is supplied with the exchange parts. The Repair
Card must be completed and returned to KUKA Deutschland GmbH.
10.2 Exchanging the motherboard
Description
The following sections describe the procedure for exchanging the mother-
board.
Equipment
The following equipment is required:

Designation Article number
Crosstip screwdriver, size 2 -
Torx T55 -
USB keyboard -
ESD wrist strap 0000-121-401
Material
Designation Article number Quantity

KPC compact + BP stick 0000-242-406 1x
Mainboard FTS D3076-K + CPU + Hs. 0000-215-838 1x
kompl.
Ep Mainboard D3445-K(Dc) 0000-284-815 1x

Repair KR C4 compact
Tightening torques
The tightening torques can be found under: (>>> 13.1 "Tightening

torques" Page 189)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.
Defective components must only be replaced with original spare parts

from KUKA Deutschland GmbH. Non-compliance nullifies warranty and lia-
bility claims.
A “Repair Card” is supplied with the exchange parts. This must be com-
pleted and returned to KUKA Deutschland GmbH together with the defec-
tive component in the following cases.
• Within the warranty period
• If, after consultation with KUKA Deutschland GmbH, an examination of
the defective component by KUKA is required.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
10.2.1 Removing the housing cover
Procedure
1. Unscrew the housing cover screws.

KR C4 compact
Repair
Fig. 10-1: Housing cover screws
1 Housing cover screws
2. Open the housing cover.
10.2.2 Removing the fan holder from the control box
Procedure
1. Remove the fastening screws from the fan holder on the control box.
Fig. 10-2: Fastening of fans
1 Fastening of the fan holder
2. Unplug the fan connections.

Fig. 10-3: Connections for fans
1 Fan connector
2 Connector for motherboard CPU fan
3. Remove the fan holder with the fans.
10.2.3 Exchanging the motherboard
Procedure
1. Remove all PC plug-in cards.

2. Disconnect all motherboard connections.
3. Remove the motherboard fastening screws.
Fig. 10-4: Motherboard fastening
1 Motherboard fastening
4. Remove motherboard from the housing and place it on a suitable

ESD-compliant support.
10.2.4 Installing the motherboard
Procedure
1. Insert a new motherboard.

KR C4 compact
Repair
Fig. 10-5: Motherboard fastening
1 Motherboard fastening
2. Plug in all motherboard connections.

3. Install all PC plug-in cards.
4. Tighten the motherboard fastening screws.
10.2.5 Installing the fan holder on the control box
Procedure
1. Plug in the fan connections.
1 Fan connector
2 Connector for motherboard CPU fan
2. Mount the fan holder with the fans.

3. Screw in the fastening screws of the fan holder.

10.2.6 Installing the housing cover
Procedure
1. Close the housing cover.
2. Screw the housing cover into place.
10.2.7 Concluding work
After the motherboard has been exchanged, the following tasks must be
carried out:
Procedure
1. Plug in USB keyboard.

KR C4 compact
Repair
2. Open BIOS menu.
3. Set date and time.
4. Load default values.
5. Carry out a function test.
10.3 Exchanging the motherboard battery
Description
The following sections describe the procedure for exchanging the mother-
board battery.
Equipment

Torx T55 -
USB keyboard -
Material
The following material is required:

Lithium metal button cell CR2032 0000-101-677 1x
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition

Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure
10.3.2 Removing the motherboard battery
Procedure
The motherboard battery is located above the processor.

KR C4 compact
Repair
1. Push the retaining spring on the battery holder upwards with a small
flat-blade screwdriver and remove the battery.
Fig. 10-10: Lithium button cell
1 Battery
2 Retaining spring and battery holder
10.3.3 Inserting the motherboard battery
Procedure
1. Label the new battery with the installation date and insert it into the
battery holder. When the battery is inserted, the retaining spring must
click into place.
Fig. 10-11: Lithium button cell
1 Battery
2 Retaining spring and battery holder
Procedure

After the battery has been exchanged, the following tasks must be carried
out:
Procedure
1. Plug in USB keyboard.

2. Open BIOS menu.
3. Set date and time.
4. Load default values.
10.4 Exchanging the RAM
Description
The following sections describe the procedure for exchanging the RAM.
Equipment

Torx T55 -
Material

KR C4 compact
Repair
Memory 2GB, DDR3 0000-198-620 1x
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)

Procedure
10.4.2 Removing RAM
Procedure
1. Using your thumbs, carefully open the retaining clips in the direction
indicated by the arrows.
2. The RAM is released and lifted out of its socket.
Fig. 10-14: Removing the RAM

KR C4 compact
Repair
1 Retaining clip
2 RAM
3. Place the RAM on an ESD mat.
Fig. 10-15: RAM removed
10.4.3 Inserting RAM
Procedure
1. Carefully insert the new RAM into the slot.

2. Close retaining clips.
Procedure
After the RAM has been exchanged, the following tasks must be carried
out:

Procedure
1. Switch on the controller and check the settings.

10.5 Exchanging the hard drive
Description
The following sections describe the procedure for exchanging the hard
drive.
Equipment

Torx T55 -
Material

KPC MC - SSD assy 0000-195-245 1x
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition

KR C4 compact
Repair
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure
10.5.2 Removing the hard drive
Procedure
1. Disconnect the power supply and data cable.

Fig. 10-18: Exchanging the hard drive
1 SATA connector
2 Power supply connector
3 Knurled screws on the underside
2. Remove the fastening screws of the hard drives.

3. Remove the hard drives.
10.5.3 Installing the hard drive
Procedure
1. Insert new hard drive.

2. Insert the fastening screws of the hard drives.
3. Screw the hard drive to the housing.
Fig. 10-19: Exchanging the hard drive
1 SATA connector
2 Power supply connector
3 Knurled screws on the underside
4. Plug in the power supply and data cable.
Procedure

KR C4 compact
Repair
After the hard drive has been exchanged, the following tasks must be car-
ried out:
Procedure

10.6 Exchanging the CCU sr
Description
The following sections describe the procedure for exchanging the CCU sr.
Equipment

Torx T55 -
Material

KRC4 compact CCUsr complete 0000-235-633 1x

Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure

KR C4 compact
Repair
10.6.2 CCU sr connections
Fig. 10-22: Connections on the CCU_SR
Con-
Item Description
nector
1 X46 KSB RoboTeam (yellow)
2 X48 KSB EtherCAT interface (green), optional
3 X45 KSB RoboTeam (red)
4 X29 EDS connection, memory card

Con-
Item Description
nector
5 X23 Fast Measurement inputs 1 to 5
6 X4 Power supply to KPC and power supply fan
7 X307 UL lamp (optional)
8 X12 USB
9 X500 Not used
10 X501 Not used
11 X21 Power supply to RDC/EMD
12 X402 Safe inputs 1 to 3
15 X401 Mastering reference switch
16 X407 Safe input 11, teach pendant plugged in
17 X406 Safe outputs 12 to 15
18 X34 KCB RDC interface (white)
19 X31 KCB KPC interface (blue)
20 X32 KCB KPP interface (orange)
21 X33 I/O board (optional)
22 X41 KSB KPC interface (yellow)
23 X47 KSB spare (red)
24 X44 KSB KEI (white)
25 X43 KSB - KSI (blue)
26 X42 KSB - KOI (orange)
27 X3 Power supply to KPP_SR logic/brakes
28 X5 Power supply to options
29 X22 Power supply to options
30 X305 Battery infeed
31 X6 I/O board power supply without battery backup
(optional)
32 X301 24 V supply, spare
33 X1 Power supply
34 X15 Power supply to power supply fan
35 X14 Power supply to external fan
36 X308 External power supply
37 X1700 Board connection to the PMB_SR
38 X405 Safe contactor output 10, single-channel input 10
39 X306 smartPAD power supply
40 X302 I/O board power supply with battery backup (op-
tional)
41 X25 Alarm contact, Power OK, power supply unit

KR C4 compact
Repair
10.6.3 Removing the CCU sr
Procedure
1. Unlock the data cable connectors. Unplug all connections to the CCU
sr.
NOTICE
Unplugging the data cable connectors without first unlocking them
damages the connectors. Unlock the connectors before unplugging
them.
Fig. 10-23: Connector locking mechanism of data cable
1 Data connector unlocked

2 Data connector locked
2. Remove the screws from the fastening plate and remove the plate to-
gether with the CCU sr.
Fig. 10-24: CCU_SR fastening
1 CCU sr fastening
10.6.4 Installing the CCU sr
Procedure
1. Check the new CCU sr for mechanical damage. Insert the fastening
plate with the CCU sr and screw it firmly in place.

Fig. 10-25: CCU_SR fastening
1 CCU sr fastening
2. Plug in all the connections in accordance with the connector and cable
labeling. Lock the data cable connectors.
Fig. 10-26: Connector locking mechanism of data cable
1 Data connector unlocked

2 Data connector locked
Procedure

KR C4 compact
Repair
After the CCU sr has been exchanged, the following tasks must be
carried out:
Procedure

10.7 Exchanging the battery
Description
The following sections describe the procedure for exchanging the battery.
Equipment

Torx T55 -
Material

Battery 2.6-12 0000-141-841 2x

Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure

KR C4 compact
Repair
10.7.2 Removing the battery
Procedure
1. Unfasten the Velcro strip.

2. Unplug the battery connection cables.
Fig. 10-29: Battery blocks, fastening and connections
1 Velcro strip for battery fastening

2 Battery connection cables
3. Remove both battery blocks.

The battery blocks must both be exchanged together.
10.7.3 Inserting the battery
Procedure
1. Insert new battery blocks.

2. Fasten the Velcro strip.

3. Plug in the battery connection cables in accordance with the cable la-
bels.
Fig. 10-30: Battery polarity
1 Connection G3.2
2 Connection G3.1
10.7.4 Battery storage
Storage
NOTICE
Destruction of the batteries due to exhaustive discharge
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, recharge the batteries
every 9 months.
Procedure

KR C4 compact
Repair
After the battery blocks have been exchanged, the following tasks must
be carried out:
Procedure

10.8 Exchanging the network card
Description
The following sections describe the procedure for exchanging the network
card.
Equipment

Torx T55 -
Material

Dual GbE - Network Card D2735 0000-204-469 1x

Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure

KR C4 compact
Repair
10.8.2 Removing the network card
Procedure
1. Remove cover of network connections.

2. Unplug the network card connections.
Fig. 10-33: Dual GbE network card connections
1 Connector KCB
2 Connector KSB
3. Release the fastenings of the network card and pull the card out of
the slot.

10.8.3 Installing a network card
Procedure
1. Inspect the new network card for mechanical damage.

2. Insert the network card into its slot and tighten the fastening screws.
Fig. 10-34: Dual GbE network card connections
1 Connector KCB
2 Connector KSB
3. Plug in the connections to the network card.
Procedure

KR C4 compact
Repair
After the network card has been exchanged, the following tasks must be
carried out:
Procedure

10.9 Exchanging the power supply unit
Description
The following section describes the procedure for exchanging the power
supply unit.
Equipment

Torx T55 -
Material

Power supply 230V - 27V + PC- supply 0000-205-143 1x
Tightening torques

torques" Page 189)
en.
ones.

bility claims.


Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure

KR C4 compact
Repair
10.9.2 Removing the power supply unit
Procedure
1. Unplug the connections on the power supply unit.

2. Unplug the power supply connections from the low-voltage power sup-
ply unit to the motherboard and hard drive.
3. Remove the fastening screws from the outside of the power supply
unit.
Fig. 10-37: Connections for low-voltage power supply
1 Connections to the motherboard

2 Connections on the power supply unit
4. Take out the power supply unit.
10.9.3 Installing the power supply unit
Procedure
1. Insert and fasten the new power supply unit.
Fig. 10-38: Low-voltage power supply unit, fastening
1 Fastening screws for power supply unit
2. Plug in the connections on the power supply unit, hard drive and
motherboard in accordance with the connector and cable labeling.

Procedure
After the power supply unit has been exchanged, the following tasks must
be carried out:
Procedure

10.10 Exchanging the mains filter
Description
The following section describes the procedure for exchanging the mains
filter.
Equipment

Torx T55 -
Socket wrench, including ratchet, size 7 -

KR C4 compact
Repair
Material

KRC4 compact mains filter drive box 0000-206-323 1x
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)

10.10.1 Removing the control box from the drive box
Procedure
1. Remove the upper fastening screws from the connecting plate on the
rear.
2. Remove the upper 3 fastening screws from the handle brackets on the
left-hand and right-hand side. Slacken the lower screws.
Fig. 10-40: Fastening screws for handle brackets and connecting

plate
1 Lower fastening screws on handle bracket

2 Upper fastening screws on handle bracket
3 Connecting plate
4 Upper fastening screws at rear
3. Lift the control box and swivel it to the rear.
Fig. 10-41: Drive box and control box separated
1 Control box
2 Handle bracket
10.10.2 Removing the mains filter
Procedure
1. Remove the mains filter fastener.

KR C4 compact
Repair
Fig. 10-42: Mains filter fastener
1 Mains filter fastener

2 Mains filter connections
2. Disconnect mains filter connections and remove mains filter from the
drive box.
10.10.3 Installing the mains filter
Procedure
1. Install new mains filter into the drive box and fasten it.
Fig. 10-43: Mains filter fastener
1 Mains filter fastener

2 Mains filter connections
2. Connect the mains filter connections.
10.10.4 Assembling control box and drive box
Procedure
1. Place the control box on the drive box.

1 Control box
2 Handle brackets
2. Insert and tighten the upper 3 fastening screws into the handle brack-
ets on the left-hand and right-hand side. Insert and tighten the lower
fastening screws.
3. Insert and tighten the fastening screws on the rear side of the con-
necting plate.

plate

3 Connecting plate
After the mains filter has been exchanged, the following tasks must be
carried out:
Procedure


KR C4 compact
Repair
10.11 Exchanging the mains filter with plug-in connector
Description
The following sections describe the procedure for exchanging the mains
filter with plug-in connector.
Equipment

Torx T55 -
Material

Mains filter with connector C20F UL/CSA 0000-138-445 1x
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition

Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
10.11.1 Removing the mains filter with plug-in connector
Procedure
1. Remove the fastening screws from the plug-in connector.
Fig. 10-46: Plug-in connector fastening
1 Fastening screws of mains filter with plug-in connector
2. Push mains filter with plug-in connector forwards through the opening
and unplug connections.

KR C4 compact
Repair
Fig. 10-47: Connections of mains filter with plug-in connector
3. Remove the mains filter with plug-in connector.
10.11.2 Installing the mains filter with plug-in connector
Procedure
1. Plug in connections at new mains filter with plug-in connector.
Fig. 10-48: Connections of mains filter with plug-in connector
1 Connections of mains filter with plug-in connector
2. Push mains filter with plug-in connector into the opening and fasten it.
Fig. 10-49: Plug-in connector fastening

After the mains filter with plug-in connector has been exchanged, the fol-
lowing tasks must be carried out:
Procedure

10.12 Exchanging the control box fans
Description
The following sections describe the procedure for exchanging the fans of
the control box.
Equipment

Torx T55 -
Material

CPU fan 4412/2HP-570 0000-212-626 1x
(PC fan)
24V DC-axial fan 4414F/2L 1x
0000-202-342
(PC fan)
Tightening torques

torques" Page 189)
en.
ones.

bility claims.

KR C4 compact
Repair
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure

10.12.2 Removing the control box fans
Procedure
1. Remove the fastening screws from the fan holder.
1 Fan connector
2 Connector for motherboard PC fan

4. Unscrew inner and outer fan grilles.
10.12.3 Installing the control box fans
Procedure
1. Screw the inner and outer fan grilles to new fans.

2. Install and fasten the new fans with the fan holder.

KR C4 compact
Repair
1 Fan connector
2 Connector for motherboard PC fan
4. Insert and tighten the fastening screws of the fan holder.
Procedure

After the fans of the control box have been exchanged, the following tasks
must be carried out:
Procedure

10.13 Exchanging the drive box fans
Description
This work instruction describes the procedure for exchanging the fans in
the drive box. There are 2 fans installed in the drive box that must be ex-
changed at the same time for maintenance. In the case of a defect, it is
also possible to exchange a single fan.
Equipment

Torx T55 -
Material

KR C4 compact
Repair
24V DC-axial fan 8414N/2HP 0000-206-321 2x
(drive box fan)
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)

Procedure
rear.

plate

3 Connecting plate
1 Control box
2 Handle bracket
10.13.2 Removing the drive box fan
Procedure
1. Remove the fastening screws from the fan holder.

KR C4 compact
Repair
Fig. 10-59: Connection for fans
1 Cable strap
2 Fan connector

4. Unscrew the fan grille.
10.13.3 Installing the drive box fan
Procedure
1. Screw the fan grille onto the new fan.

2. Install and fasten the new fan with the fan holder.
Fig. 10-60: Connection for fans
1 Cable strap
2 Fan connector
4. Insert and tighten the fastening screws of the fan holder.

Procedure
1 Control box
2 Handle brackets
fastening screws.
necting plate.

KR C4 compact
Repair
plate

3 Connecting plate
10.13.5 Concluding work for exchange of drive box fan
After the fan of the drive box has been exchanged, the following tasks
must be carried out:
Procedure
• Switch on the controller and check the settings.

• Carry out a function test.
10.14 Exchanging the KPP sr
Description
The following sections describe the procedure for exchanging the KPP sr.
Equipment

Torx T55 -
Material

KPP sr 0000-205-445 1x
Tightening torques

torques" Page 189)

KR C4 compact
Repair
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure
rear.

KR C4 compact
Repair
plate

3 Connecting plate
1 Control box
2 Handle bracket
10.14.2 Removing the KPP sr
Procedure
1. Unplug the connections on the KPP sr.

2. Remove the fastening screws of the KPP sr card.

Fig. 10-66: Fastening the KPP_SR
1 Fastening screws on the KPP sr
10.14.3 Installing the KPP sr
Procedure
1. Insert and fasten new KPP sr.
Fig. 10-67: Fastening the KPP_SR
2. Plug in all the connections in accordance with the cable labeling and
circuit diagram.
Procedure

KR C4 compact
Repair
1 Control box
2 Handle brackets
fastening screws.
necting plate.

plate

3 Connecting plate
After the KPP sr has been exchanged, the following tasks must be carried
out:
Procedure


10.15 Exchanging the KSP sr + heat exchanger
Description
The following sections describe the procedure for exchanging the KSP sr
including heat exchanger.
Equipment

Torx T55 -
Material

KSPsr + heat exch. cooling profile assy 0000-215-837 1x
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition

KR C4 compact
Repair
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure
rear.

plate

3 Connecting plate

1 Control box
2 Handle bracket
10.15.2 Removing the KSP sr + heat exchanger
Procedure
1. Unplug the connections on the KSP sr + heat exchanger.

2. Remove fastening screws from the KSP sr + heat exchanger.
Fig. 10-72: Fastening the KSP_SR
1 Fastening screws on the KSP sr + heat exchanger
3. Take out the KSP sr + heat exchanger.
10.15.3 Installing the KSP sr + heat exchanger
Procedure
1. Insert and fasten new KSP sr + heat exchanger.

KR C4 compact
Repair
Fig. 10-73: Fastening the KSP_SR
1 Fastening screws on the KSP sr + heat exchanger
2. Plug in all the connections in accordance with the connector and cable
labeling.
Procedure
1 Control box
2 Handle brackets
fastening screws.
necting plate.


plate

3 Connecting plate
After the KSP sr + heat exchanger has been exchanged, the following
tasks must be carried out:
Procedure

10.16 Exchanging the brake resistor
Description
The following sections describe the procedure for exchanging the brake
resistor.
Equipment

Torx T55 -
Hexagon socket wrench, size 7 -
Material

25 ohm brake resistor 0000-206-346 1x

KR C4 compact
Repair
Tightening torques

torques" Page 189)
en.
ones.

bility claims.
Precondition
Work safety
WARNING
ries or even death.
NOTICE
charge (ESD)
Procedure
rear.


plate

3 Connecting plate
1 Control box
2 Handle bracket
10.16.2 Removing the brake resistor
Procedure
1. Remove the fastening screws from the brake resistor.

2. Unplug the brake resistor connections.

KR C4 compact
Repair
Fig. 10-78: Brake resistor fastening
1 Fastening screws on brake resistor

2 Brake resistor connection
3 Cable strap
3. Remove the brake resistor from the drive box.
10.16.3 Installing the brake resistor
Procedure
1. Install new brake resistor into the drive box and screw it firmly in
place.
2. Plug in the brake resistor connection.
3. Secure connecting cables with cable strap.
Fig. 10-79: Brake resistor fastening
1 Fastening screws on brake resistor

2 Brake resistor connection
3 Cable strap

Procedure
1 Control box
2 Handle brackets
fastening screws.
necting plate.

plate

3 Connecting plate
After the brake resistor has been exchanged, the following tasks must be
carried out:

KR C4 compact
Repair
Procedure

10.17 Installing the KUKA System Software (KSS)
Further information is contained in the operating and programming in-

structions for the KUKA System Software (KSS).


KR C4 compact
Troubleshooting
11 Troubleshooting
11.1 LED display on Cabinet Control Unit, Small Robot
Overview
Fig. 11-1: CCU_SR LED display
Item Designation Color Description Remedy

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

Troubleshooting KR C4 compact

4 L/A Green • On = physical connec- -
KSB tion. Network cable
plugged in
5 L/A Green
• Off = no physical con-
100 Mbit
KSB KPC-MC nection. Network cable
Orange not 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 external
supply voltage (rated
voltage 24 V)
On = supply voltage present -
present
CIB_SR present
• Check fuse F308
voltage 24 V)
present
CIB_SR present
• Check fuse F308
voltage 24 V)
9 PWRS/3.3V Green On = power supply present -
Off = no supply voltage • Check fuse F17-3
present
• If the LED PWR/3.3V
lights up, exchange the
CCU_SR module

KR C4 compact
Troubleshooting
10 STAS2 Orange Off = no supply voltage • Check fuse F17-3
present
Safety node B • If the LED PWR/3.3V
CCU_SR module
Flashing at 1 Hz = normal -
state
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
CCU_SR module
state
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 • On = physical connec- -
KCB tion
• Off = no physical con-
14 KSB smart- Green
nection. Network cable
PAD_MC 100 Mbit
not plugged in.
Orange
• Flashing = data traffic
1 Gbit
on the line
15 L/A Green
KSB


16 RUN CIB_SR Green On = operational (normal -
state)
EtherCat
ATμC I/O Off = Init (after switching -
node on)
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
state
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
CCU_SR module
Flashing at 1 Hz = normal
state
Flashing at 10 Hz = boot
phase
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)

KR C4 compact
Troubleshooting
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
state
phase
nal)
24 PWR/5V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V)
Power supply
for PMB_SR Flashing at 1 Hz = normal -
state
phase
Flashing = fault code (inter- -
nal)
25 - - Not used --
26 - - Not used
27 Fuse LEDs Red On = fuse defective Exchange defective fuse
The LEDs in- Off = fuse OK -
dicate the sta-
tus of the
fuses.
11.2 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.

Fig. 11-2: Arrangement of the fuses
Item Designation Description Fusing

1 F306 smartPAD power supply 2 A
2 F302 I/O board power supply (op- 5 A
tional)
3 F3-1 KPP_SR and KSP_SR brakes 15 A
without battery backup
4 F5-1 24 V without battery backup, 15 A
for options
5 F4-1 KPC with battery backup 10 A
6 F307 UL lamp (optional) 2 A
7 F4-2 24 V with battery backup, for 2 A
fans
8 F22 24 V without battery backup, 7.5 A
for options
9 F5-2 24 V with battery backup, for 7.5 A
options
10 F3-2 KPP_SR and KSP_SR logic 7.5 A
with battery backup
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 External fans (optional) 7.5 A
16 F6 I/O board power supply (op- 7.5 A
tional)
17 F21 RDC power supply 3 A
18 F305 Battery infeed 15 A

KR C4 compact
Troubleshooting
Item Designation Description Fusing
19 F301 24 V without battery backup, 10 A
for options
20 F15 Power supply unit fan 2 A
21 F308 External power supply 7.5 A


KR C4 compact
Decommissioning, storage and disposal

12 Decommissioning, storage and disposal
12.1 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.
12.2 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.

Decommissioning, storage and disposal KR C4 compact
8. Cover the robot controller with plastic film and seal it against dust.
If necessary, add a desiccant beneath the sheeting.
12.3 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.
Material Subassembly, component Additional information

Metals
CuZn Connectors, contacts Dispose of without disman-
(gold-plated) tling
Copper Electrical cables, wires
Steel Screws, washers, robot
controller housing
Steel Allen screws, washers
(ST 52-3)
Electrical components
Electronic components, Dispose of as electrical
such as RDC, EDS, circuit scrap without disassem-
board bling
Plastics
EPDM Seals and covers
ETFE Flexible tube
NBR O-rings
PE Cable straps
PUR Cable sheaths

KR C4 compact
Appendix
13 Appendix
13.1 Tightening torques
Tightening torques
The following tightening torques (Nm) are valid for screws and nuts where
no other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and
coated (e.g. mech. galv., zinc flake plating) screws and nuts.
Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm
Strength class
Thread 8.8 10.9
ISO7991 ISO7380, ISO07381
Allen screw Fillister head
screw
M3 0.8 Nm 0.8 Nm
M4 1.9 Nm 1.9 Nm
M5 3.8 Nm 3.8 Nm
Strength class
Thread 10.9
DIN7984
pan head screws
M4 2.8 Nm
Tighten M5 domed cap nuts with a torque of 4.2 Nm.
13.2 Applied standards and regulations
For reasons of completeness, the table also contains the applied US and
Canadian standards and regulations.

Appendix KR C4 compact
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
2014/68/EU:2014 Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)
ANSI/RIA R15.06-2012 Industrial Robots and Robot Systems
CAN/CSA-C22.2 No. Safety Requirements for Electrical Equipment for

61010-1:2012 Measurement, Control, and Laboratory Use
Part 1: General Requirements
CAN/CSA-C22.2 No. Safety Requirements for Electrical Equipment for

61010-2-201:12 Measurement, Control, and Laboratory Use
Part 2-201: Particular Requirements for Control Equipment
CAN/CSA-Z434-14 Industrial Robots and Robot Systems:

General Safety Requirements
EN 60204-1:2006/ Safety of machinery:

A1:2009
Electrical equipment of machines - Part 1: General requirements
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 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles
EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery:

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

KR C4 compact
Appendix
EN ISO 13849-2:2012 Safety of machinery:
Safety-related parts of control systems - Part 2: Validation
EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design
NFPA 79:2018 Electrical Standard for Industrial Machinery
UL 1740:2018 Robots and Robotic Equipment
UL 1998:2013 Standard for Safety:

Software in Programmable Components
UL 61010-1:2012 Safety Requirements for Electrical Equipment for

Measurement, Control, and Laboratory Use
Part 1: General Requirements
UL 61010-2-201:2014 Safety Requirements for Electrical Equipment for

Measurement, Control, and Laboratory Use
Part 2-201: Particular Requirements for Control Equipment

Appendix KR C4 compact

KR C4 compact
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
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KR C4 compact

KR C4 compact
Index Control box fans, exchanging...................... 154

Control PC................................................13, 15
19" rack.................................................... 64, 94
Control PC, functions..................................... 15
2006/42/EC:2006.......................................... 190
Control unit..................................................... 56
2014/30/EU:2014.......................................... 190
Cooling............................................................22
2014/68/EU:2014.......................................... 190
Cooling circuit................................................. 22
95/16/EC....................................................... 190
Counterbalancing system............................... 51
A
Accessories.............................................. 13, 25
D
ANSI/RIA R15.06-2012................................ 190 Danger zone................................................... 27
Appendix....................................................... 189 Data cable X21...............................................96
Applied standards and regulations.............. 189 DC...................................................................16
Automatic mode..............................................50 Declaration of conformity............................... 25
Axis limitation, mechanical............................. 38 Declaration of incorporation.....................25, 26
Axis range.......................................................26 Decommissioning................................... 52, 187
defective fuses..............................................183
Description. 113, 119, 122, 126, 129, 135, 139,
143, 146, 151, 154, 158, 163, 168, 172
B Description of the industrial robot..................13
Basic data.......................................................55 Device connection cable................................ 17
Batteries..........................................................16 Dimensions..................................................... 57
Battery discharge protection, reversing......... 97 Dimensions, handle brackets......................... 59
Battery, exchanging...................................... 135 Dimensions, smartPAD holder....................... 59
Battery, exhaustive discharge................56, 138 Disposal......................................... 52, 187, 188
Brake defect................................................... 41 Documentation, industrial robot....................... 9
Brake release device......................................39 Drive box........................................................ 16
Brake resistor, exchanging...........................172 Drive box fans, exchanging......................... 158
Braking distance............................................. 26 Drive Configuration ....................................... 16
Dual NIC......................................................... 10
Dynamic testing.............................................. 74
C
Cabinet Control Unit LED display................179
Cabinet Control Unit Small Robot, fuses.... 183 E
Cabinet Control Unit, Small Robot................ 15 EA................................................................... 11
Cabinet Interface Board, Small Robot.... 15, 58 EC declaration of conformity......................... 25
Cable lengths........................................... 57, 66 EDS.................................................................10
CAN/CSA-C22.2 No. 61010-1:2012............ 190 Electrical Standard for Industrial
CAN/CSA-C22.2 No. 61010-2-201:12......... 190 Machinery..................................................... 191
CAN/CSA-Z434-14....................................... 190 Electromagnetic compatibility (EMC)........... 190
CCU sr, exchanging..................................... 129 Electromagnetic compatibility (EMC):.......... 190
CCU_SR...................................................10, 15 Electromagnetic compatibility, EMC...............63
Functions................................................... 15 EMC................................................................ 10
CCU_SR LED display, overview..................179 EMC Directive........................................ 26, 190
CCU_SR relay outputs, checking................ 109 EMD................................................................ 10
CE mark..........................................................26 EMERGENCY STOP....................................102
Charge............................................................ 16 EMERGENCY STOP device............. 34, 35, 41
CIB_SR.....................................................10, 58 EMERGENCY STOP devices to X11............ 71
Inputs......................................................... 58 EMERGENCY STOP wiring example............71
Outputs...................................................... 58 EMERGENCY STOP, external................ 35, 45
CIB_SR, safe input.........................................73 EMERGENCY STOP, local............................ 45
CIB_SR, safe output...................................... 75 EN 60204-1:2006/A1:2009........................... 190
CIP Safety...................................................... 10 EN 61000-6-2:2005...................................... 190
CK, monitoring................................................37 EN 61000-6-4:2007 + A1:2011.................... 190
Cleaning work.................................................51 EN 614-1:2006+A1:2009..............................190
Connecting cables............................. 13, 25, 95 EN ISO 10218-1:2011.................................. 190
Connection conditions.................................... 65 EN ISO 12100:2010..................................... 190
Connection manager.................................... 102 EN ISO 13849-1:2015..................................190
Connection panel............................................13 EN ISO 13849-2:2012..................................191
Control box..................................................... 14 EN ISO 13850:2015..................................... 191

KR C4 compact
Enabling device........................................35, 41 KOI.................................................................. 11

Enabling device, external............................... 37 KONI............................................................... 11
Enabling switches.................................... 35, 80 KPC.................................................................11
Environmental conditions............................... 55 KPP sr, exchanging......................................163
Equipment.. 113, 119, 122, 126, 129, 135, 139, KPP_SR.......................................................... 11
143, 146, 151, 154, 158, 163, 168, 172 KSB................................................................. 11
Equipotential bonding, connecting................. 94 KSI.................................................................. 86
Ethernet interface KSP sr + heat exchanger, exchanging....... 168
X66 (RJ45)................................................ 84 KSP_SR.......................................................... 11
External axes..................................................25 KSS................................................................. 11
External axis................................................... 28 KUKA Customer Support............................. 193
External enabling switch, function................. 70 KUKA Service...............................................193
KUKA Service Interface, X69........................ 86
KUKA smartPAD........................11, 27, 56, 101
F KUKA smartPAD-2................................... 11, 27
Faults.............................................................. 42
Filter mats.......................................................22
Function test................................................... 44 L
Fusing............................................................. 67 Labeling.......................................................... 39
Liability............................................................ 25
Linear unit.......................................................25
G Low-voltage power supply unit...................... 16
General safety measures............................... 41 Low Voltage Directive.....................................26
H M
Hard drive, exchanging................................ 126 Machine data.................................................. 45
Hazardous substances................................... 52 Machinery Directive................................26, 190
Mains filter...................................................... 16
Mains filter with plug-in connector,
exchanging................................................... 151
I Mains filter, exchanging................................146
Identification plate.........................................104
Maintenance........................................... 50, 107
Industrial robot......................................... 13, 25
Maintenance symbols...................................107
Industrial Robots and Robot Systems.........190
Manipulator.................................. 11, 13, 25, 27
Infeed.............................................................. 67
Manual mode..................................................49
Installation conditions..................................... 64
Mastering test................................................. 85
Installation, KUKA System Software........... 177
Material....113, 119, 122, 126, 129, 135, 139,
Installing the robot controller......................... 94
143, 147, 151, 154, 158, 163, 168, 172
Intended use...................................................23
Material designation..................................... 188
Interface
Mechanical end stops.................................... 38
EtherCAT X65............................................85
Misuse.............................................................23
Interfaces..................................................17, 19
Mode selector switch....................................102
Interfaces, control PC.....................................19
Monitoring, physical safeguards.....................33
Introduction....................................................... 9
Monitoring, velocity.........................................37
IT security....................................................... 42
Motherboard battery, exchanging.................119
Motherboard D3076-K.................................... 19
Motherboard D3236-K.................................... 20
J Motherboard D3236-K interfaces................... 20
Jog keys....................................................... 102 Motherboard D3445-K..............................21, 22
Jog mode................................................. 38, 41 Motherboard D3445-K interfaces................... 21
Motherboard, exchanging............................. 113
Motherboards..................................................19
K Motor cable, data cable................................. 17
KCB.................................................................10 Motor connector X20......................................95
KEB................................................................. 11
KEI.................................................................. 11
Keyboard.......................................................102 N
Keyboard key................................................102 Network card, exchanging............................139
KLI...................................................................11 NFPA 79....................................................... 191

KR C4 compact
O Release device............................................... 39
Operating mode selection.............................. 31 Repair..................................................... 50, 113
Operation...................................................... 101 Resolver cable, length difference............57, 66
Operator safety..................................31, 33, 41 Robot controller........................................13, 25
Operators........................................................ 30 Robot controller, cleaning.............................110
Options..................................................... 13, 25 Robot controller, switching on........................99
Overload......................................................... 41
Overview
Planning..................................................... 63 S
Overview of robot controller...........................13 Safe operational stop...............................27, 37
Overview, start-up...........................................93 Safeguard to X11........................................... 71
Safeguards, external...................................... 40
SafeOperation via Ethernet safety interface. 80
P Safety..............................................................25
Panic position................................................. 35 Safety controller..............................................32
PE equipotential bonding............................... 66 Safety functions........................................31, 41
PE, connecting............................................... 94 Safety functions, Ethernet safety interface....75
Performance level...........................................87 Safety functions, overview............................. 31
Performance Level......................................... 31 Safety gate, wiring example.......................... 72
Peripheral cables............................................17 Safety instructions............................................ 9
Peripheral contactor....................................... 48 Safety interface, X11................................67, 68
Personal protective equipment...................... 29 Safety logic..................................................... 13
Personnel........................................................29 Safety of machinery.............................190, 191
PFH values..................................................... 87 Safety options.................................................27
PL....................................................................87 Safety Requirements for Electrical Equipment
Planning.......................................................... 63 for Measurement, Control, and Laboratory
Overview.................................................... 63 Use............................................................... 191
Plant integrator............................................... 28 Safety STOP 0............................................... 27
Plates and labels............................................59 Safety STOP 1............................................... 27
PMB_SR......................................................... 11 Safety STOP 2............................................... 27
Positioner........................................................ 25 Safety STOP 0............................................... 27
Power failure...................................................16 Safety STOP 1............................................... 27
Power Management Board, Small Robot......15 Safety STOP 2............................................... 27
Power supply connection............................... 67 Safety stop, external...................................... 37
Power supply connection, technical data....55, Safety zone.............................................. 27, 30
65 Safety, general................................................25
Power supply unit, exchanging....................143 SATA connections...........................................11
Power supply with battery backup.................16 Selecting the operating mode........................32
Power supply with mains connector, Service life...................................................... 26
connection...................................................... 97 Signal “Peri enabled”......................................70
Power supply without battery backup............16 Simulation....................................................... 50
Power supply without mains connector, Single point of control.................................... 52
connection...................................................... 98 Slot assignment, motherboard D3076-K....... 20
Power supply, connecting.............................. 97 Slot assignment, motherboard D3236-K....... 21
Power switched off......................................... 16 Slot assignment, motherboard D3445-K....... 22
Power unit.......................................................13 smartPAD...................................11, 28, 41, 101
Pressure Equipment Directive............... 51, 190 smartPAD cable..............................................17
Preventive maintenance work........................ 51 smartPAD cable extensions.....................57, 66
Procurement of spare parts......................... 113 smartPAD, plugging in....................................96
Product description.........................................13 Software................................................... 13, 25
Protective equipment......................................38 Software limit switches............................ 38, 41
PSA.................................................................29 Space Mouse................................................102
Spare parts....114, 119, 123, 126, 130, 136,
140, 143, 147, 151, 154, 159, 164, 168, 173
SPOC..............................................................52
R Start-up.....................................................43, 93
RAM, exchanging......................................... 122 Start-up mode.................................................47
RDC................................................................ 11 Start-up, overview...........................................93
Reaction distance........................................... 26 Start backwards key.....................................102
Recommissioning..................................... 43, 93 Start key............................................... 102, 103

KR C4 compact
Status keys................................................... 102 X

STOP 0.................................................... 26, 28 X11, configuring and connecting....................98
STOP 1.................................................... 26, 28 X11, connector pin allocation.........................68
STOP 2.................................................... 26, 28 X11, safety interface.......................................68
Stop category 0.............................................. 28 X20, motor connector.....................................95
Stop category 1.............................................. 28 X21, connector pin allocation........................ 96
Stop category 2.............................................. 28 X21, Data cable..............................................96
Stop category 1, Drive Ramp Stop............... 28 X65
STOP key..................................................... 102 EtherCAT................................................... 85
Stop reactions.................................................30 X66
STOP 1 - DRS............................................... 28 Ethernet interface (RJ45)..........................84
Stopping distance.................................... 26, 30 X69, KSI......................................................... 86
Storage................................................... 52, 187
Storage of batteries......................................138
Support request............................................ 193
System integrator.............................. 26, 28, 29
T
T1 (operating mode).......................................28
T2 (operating mode).......................................28
Target group..................................................... 9
Teach pendant......................................... 13, 25
Technical data.................................................55
KUKA smartPAD........................................56
Terms used..................................................... 10
Terms, safety.................................................. 26
Test output A.................................................. 68
Test output B.................................................. 68
Tightening torques........................................189
Touch screen................................................ 101
Trademarks..................................................... 10
Training............................................................. 9
Transportation.......................................... 43, 91
Troubleshooting............................................ 179
Turn-tilt table...................................................25
U
UL 61010-1:2012..........................................191
UL 61010-2-201:2014...................................191
UL 1740:2018............................................... 191
UL 1998:2013............................................... 191
US2................................................................. 48
USB.................................................................11
User.......................................................... 26, 29
V
Velocity monitoring......................................... 37
Vibration resistance........................................ 56
W
Warnings........................................................... 9
Work safety....114, 120, 123, 127, 130, 136,
140, 144, 147, 152, 155, 159, 164, 169, 173
Workspace................................................26, 30

BA KR C4 Compact En-2

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Controller

Publication: Pub BA KR C4 compact (PDF) en

Book structure: BA KR C4 compact V12.2

Version: BA KR C4 compact V14

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3.6 Additional protective equipment............................................................................ 38

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5.11 Performance level.................................................................................................. 87

7 Start-up and recommissioning............................................................... 93

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10.4 Exchanging the RAM............................................................................................ 122

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10.12.1 Removing the housing cover................................................................................ 155

12 Decommissioning, storage and disposal............................................. 187

14 KUKA Service........................................................................................... 193

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1.1 Target group

This documentation is aimed at users with the following knowledge and

• Advanced knowledge of electrical and electronic systems

For optimal use of KUKA products, we recommend the training courses

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

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

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

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

• Windows is a trademark of Microsoft Corporation.

• EtherCAT® is a registered trademark and patented tech-

• CIP Safety® is a trademark of ODVA.

1.5 Terms used

CIP Safety Common Industrial Protocol Safety

CCU_SR Cabinet Control Unit, Small Robot

CIB_SR Cabinet Interface Board, Small Robot

Dual NIC Dual Network Interface Card

EDS Electronic Data Storage

EMD Electronic Mastering Device

EMC Electromagnetic compatibility

KCB KUKA Controller Bus

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KEI KUKA EtherCAT Interface

KLI KUKA Line Interface

KOI KUKA Operator Panel Interface

KONI KUKA Option Network Interface

KPC KUKA control PC

KPP_SR KUKA Power Pack, Small Robot

KSB KUKA System Bus

KSP_SR KUKA Servo Pack, Small Robot

KSS KUKA System Software

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

Manipulator The robot arm and the associated electrical installations

PMB_SR Power Management Board, Small Robot

RDC Resolver Digital Converter

smartPAD Programming device for the robot controller