Controller Option KUKA Roboter GmbH

Drive Box for External Axes

For KR C4 compact
Assembly and Operating Instructions

Issued: 28.08.2014

Version: MA external axis box KR C4 compact V3

 Drive Box for External Axes

© Copyright 2014
KUKA Roboter 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 Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

Publication: Pub MA Antriebsbox für Zusatzachsen KR C4 compact (PDF) en

Book structure: MA Antriebsbox für Zusatzachsen KR C4 compact V3.1
Version: MA external axis box KR C4 compact V3

2 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 Contents

Contents
1 Introduction .................................................................................................. 5
1.1 Representation of warnings and notes ...................................................................... 5
1.2 Terms used ................................................................................................................ 5

2 Purpose ........................................................................................................ 7
2.1 Target group .............................................................................................................. 7
2.2 Intended use .............................................................................................................. 7

3 Product description ..................................................................................... 9

3.1 Description of the industrial robot .............................................................................. 9
3.2 Overview of the drive box for external axes ............................................................... 9
3.3 Description of connection panel ................................................................................. 10
3.4 Cooling ....................................................................................................................... 11

4 Technical data .............................................................................................. 13

4.1 Dimensions ................................................................................................................ 14
4.2 Minimum clearances .................................................................................................. 14
4.3 Dimensions of handle brackets .................................................................................. 15
4.4 Plates and labels ........................................................................................................ 15

5 Safety ............................................................................................................ 17
6 Planning ....................................................................................................... 19
6.1 Electromagnetic compatibility (EMC) ......................................................................... 19
6.2 Installation conditions ................................................................................................. 19
6.3 Connection conditions ................................................................................................ 20
6.4 Power supply connection via socket for non-heating appliances ............................... 21
6.5 Interfaces ................................................................................................................... 21
6.6 Options for controlling the external axes .................................................................... 23
6.7 PE equipotential bonding ........................................................................................... 24
6.8 Performance level ...................................................................................................... 25
6.8.1 PFH values of the safety functions ....................................................................... 25

7 Transportation ............................................................................................. 27
7.1 Transporting the drive box ......................................................................................... 27
7.2 Transportation without trolley ..................................................................................... 27

8 Start-up and recommissioning ................................................................... 29

8.1 Start-up overview ....................................................................................................... 29
8.2 Installing the drive box ............................................................................................... 29
8.3 Connecting the connecting cables ............................................................................. 29
8.4 Connecting the PE equipotential bonding .................................................................. 30
8.5 Connecting the drive box to the power supply ........................................................... 30
8.5.1 Connecting the drive box to the power supply with mains connector ................... 30
8.5.2 Connecting the drive box to the power supply without mains connector .............. 30
8.6 Switching on the robot controller with the drive box ................................................... 30

9 Maintenance ................................................................................................. 33
9.1 Maintenance symbols ................................................................................................ 33

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 3 / 55

 Drive Box for External Axes

9.2 Cleaning the drive box ............................................................................................... 34

10 Repair ............................................................................................................ 35
10.1 Repair and procurement of spare parts ..................................................................... 35
10.2 Exchanging the drive box fans .................................................................................. 35
10.3 Exchanging the mains filter ....................................................................................... 37
10.4 Exchanging the brake resistor ................................................................................... 38
10.5 Replacing the contactor ............................................................................................. 39
10.6 Exchanging the KPP_SR ........................................................................................... 40
10.7 Exchanging the KSP_SR ........................................................................................... 41

11 Decommissioning, storage and disposal .................................................. 43

11.1 Decommissioning ...................................................................................................... 43
11.2 Storage ...................................................................................................................... 43
11.3 Disposal ..................................................................................................................... 43

12 KUKA Service ............................................................................................... 45

12.1 Requesting support ................................................................................................... 45
12.2 KUKA Customer Support ........................................................................................... 45

Index ............................................................................................................. 53

4 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 1 Introduction

1 Introduction

1.1 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

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.

1.2 Terms used

Term Description
EMC Electromagnetic compatibility
KPP_SR KUKA Power Pack Small Robot
KSP_SR KUKA Servo Pack Small Robot
Manipulator The robot arm and the associated electrical
installations

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 5 / 55

 Drive Box for External Axes

6 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 2 Purpose

2 Purpose

2.1 Target group

This documentation is aimed at users with the following knowledge and skills:
 Advanced knowledge of electrical and electronic systems
 Advanced knowledge of the robot controller
 Advanced knowledge of the Windows operating system

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

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

2.2 Intended use

Use The drive box is intended for the KR C4 compact robot controller. This option
enables the connection of freely movable and positionable additional drives.

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

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 7 / 55

 Drive Box for External Axes

8 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 3 Product description

3 Product description

3.1 Description of the industrial robot

The industrial robot consists of the following components:

 Manipulator
 External axes
 Robot controller
 Drive box for external axes
 smartPAD teach pendant
 Connecting cables
 Software
 Options, accessories

Fig. 3-1: Example of an industrial robot

1 Manipulator
2 Data cable, Agilus
3 Motor cable, Agilus
4 Connecting cable, smartPAD
5 smartPAD teach pendant
6 Resolver cable, external axis
7 KR C4 compact robot controller
8 Data cable, drive box
9 Drive box
10 Motor cable, external axis
11 Motor, external axis

3.2 Overview of the drive box for external axes

The drive box for external axes consists of the following components:

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 9 / 55

 Drive Box for External Axes

Fig. 3-2: Overview of drive box for external axes

1 Inlet connector for non-heating 5 KPP_SR

appliances
2 Mains filter 6 KSP_SR
3 Contactor 7 Fans
4 Brake resistor 8 Connection panel

Functions The drive box performs the following functions:

 Generation of the intermediate circuit voltage
 Control of the external axes
 Control of the external axis brakes
 Checking of intermediate circuit voltage in braking mode

3.3 Description of connection panel

Overview The connection panel of the drive box consists as standard of connections for
the following cables:
 Device connection cable
 Motor cable for external axes
 Data cable for drive box
The configuration of the connection panel varies according to the customer-
specific version and the options required.

Connection panel

Fig. 3-3: Connection panel, drive box

10 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 3 Product description

1 X28 Data interface to additional drive box (variant)

2 X29 Data interface, drive box
3 X1 Power supply connection
4 X7.1 Motor connection, external axis 1
5 X7.2 Motor connection, external axis 2 (variant)
6 Equipotential bonding connection

All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor di-
odes. RC elements and VCR resistors are not suitable.

3.4 Cooling

Description The drive box is cooled by ambient air with the aid of 2 fans.

Upstream installation of filter mats at the ventilation slits

causes an increase in temperature, leading to a reduc-
tion in the service life of the installed devices!

Cooling circuit

Fig. 3-4: Cooling circuit, drive box

1 Air inlet 3 Air outlet

2 Fans

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 11 / 55

 Drive Box for External Axes

12 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 4 Technical data

4 Technical data
Basic data Cabinet type Drive box for external axes
Color RAL 7016
Number of axes max. 2
Weight 14 kg
Protection rating IP 20
Sound level according to average: 54 dB (A)
DIN 45635-1

Power supply The drive box may only be connected to grounded-neutral power supply sys-
connection tems.

Rated supply voltage 200 V - 230 V AC, single-phase,

two-phase (with grounded neutral
(as symmetrical as possible)
between 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
Thermal power dissipation max. 200 W
Mains-side fusing 2x 16 A slow-blowing (1 (2)x phase;
1x neutral conductor (optional))
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit

Environmental Ambient temperature during opera- +5 ... 45 °C (278 ... 318 K)

conditions tion
Ambient temperature during stor- -25 ... +70 °C (248 ... 343 K)
age/transportation
Temperature change max. 1.1 K/min
Humidity class 3k3 acc. to DIN EN 60721-3-3;
1995
Altitude  up to 1000 m above mean sea
level with no reduction in power
 1000 m ... 4000 m above mean
sea level with a reduction in
power of 5%/1000 m

Vibration resis- Type of loading During transpor- During continuous

tance tation operation
r.m.s. acceleration (sus- 0.37 g 0.1 g
tained oscillation)
Frequency range (sustained 4 to 120 Hz
oscillation)
Acceleration (shock in X/Y/Z 10 g 2.5 g
direction)
Waveform/duration (shock Half-sine/11 ms
in X/Y/Z direction)

If more severe mechanical stress is expected, the controller must be installed

on anti-vibration components.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 13 / 55

 Drive Box for External Axes

Cable lengths The following cable sets are available for connecting the drive box to the
KR C4 compact robot controller:

KR C4 compact data cable X28- 0.45 m; 7 m; 15 m; 25 m

X29

The drive box may only be connected with the cable sets intended for this pur-
pose.

4.1 Dimensions

The dimensions of the drive box are indicated in the diagram (>>> Fig. 4-1 ).

Fig. 4-1: Dimensions

1 Top view
2 Front view
3 Side view

4.2 Minimum clearances

The minimum clearances that must be maintained for the drive box are indi-
cated in the diagram (>>> Fig. 4-2 ).
Both sides of the drive box must be accessible to the cooling air. Clearance of
70 mm on each side.

14 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 4 Technical data

Fig. 4-2: Minimum clearances

If the minimum clearances are not maintained, this can

result in damage to the drive box. The specified minimum
clearances must always be observed.

4.3 Dimensions of handle brackets

Fig. 4-3: Dimensions of handle brackets

4.4 Plates and labels

Overview The following plates and labels are attached to the drive box:

Designations

Fig. 4-4: Plates and labels

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 15 / 55

 Drive Box for External Axes

Plate no. Designation

1 Rating plate on drive box
2 Note: Unplug mains connector before opening the housing!

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

16 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 5 Safety

5 Safety
This documentation contains safety instructions which refer specifically to the
product described here. The fundamental safety information for the industrial
robot can be found in the “Safety” chapter of the operating or assembly instruc-
tions for the robot controller.

The “Safety” chapter in the operating instructions or as-

sembly instructions of the robot controller must be ob-
served. Death to persons, severe injuries or considerable damage to
property may otherwise result.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 17 / 55

 Drive Box for External Axes

18 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 6 Planning

6 Planning
Overview Step Description Information
1 Electromagnetic compatibility (>>> 6.1 "Electromagnetic
compatibility (EMC)"
Page 19)
2 Installation conditions (>>> 6.2 "Installation condi-
tions" Page 19)
3 Connection conditions (>>> 6.3 "Connection condi-
tions" Page 20)
4 Power supply connection (>>> 6.4 "Power supply con-
nection via socket for non-
heating appliances" Page 21)
5 Interfaces (>>> 6.5 "Interfaces"
Page 21)
6 Options for controlling the (>>> 6.6 "Options for con-
external axes trolling the external axes"
Page 23)
7 PE equipotential bonding (>>> 6.7 "PE equipotential
bonding" Page 24)
8 Performance Level (>>> 6.8 "Performance
level" Page 25)

6.1 Electromagnetic compatibility (EMC)

Description Only connecting cables provided by KUKA Roboter GmbH may be used for
the connection of the drive box.

The robot controller corresponds to EMC class A, Group 1, in accor-

dance with EN 55011 and is intended for use in an industrial setting.
Ascertaining the electromagnetic compatibility in other environments
can result in difficulties due to conducted and radiated disturbance that may
occur.

6.2 Installation conditions

Description The drive box can be installed in a 19" rack or as a standalone device. If the
drive box is to be installed in a 19" rack, the depth must be at least 600 mm.
The drive box can be installed either beneath or next to a KR C4 compact ro-
bot controller. The specifications in the “Technical data” chapter must be ob-
served. The drive box may only be installed and operated in the horizontal
position.
The dimensions of the drive box are indicated in the diagram (>>> Fig. 6-1 ).

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 19 / 55

 Drive Box for External Axes

Fig. 6-1: Dimensions

1 Top view
2 Front view
3 Side view

The minimum clearances that must be maintained for the drive box are indi-
cated in the diagram (>>> Fig. 6-2 ).
Both sides of the drive box must be accessible to the cooling air. Clearance of
70 mm on each side.

Fig. 6-2: Minimum clearances

If the minimum clearances are not maintained, this can

result in damage to the drive box. The specified minimum
clearances must always be observed.

6.3 Connection conditions

Power supply The drive box may only be connected to grounded-neutral power supply sys-
connection tems.

20 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 6 Planning

Rated supply voltage 200 V - 230 V AC, single-phase,

two-phase (with grounded neutral
(as symmetrical as possible)
between 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
Thermal power dissipation max. 200 W
Mains-side fusing 2x 16 A slow-blowing (1 (2)x phase;
1x neutral conductor (optional))
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective ground conduc-
tors is the reference bus of the
power unit

6.4 Power supply connection via socket for non-heating appliances

Description For connection to the mains, the drive box is equipped with a 3-pole socket for
non-heating appliances. The drive box must be connected to the mains via the
device connection cable included in the scope of supply.
The drive box can be connected to the mains via the following device connec-
tion cable:
 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 (option-

al))

6.5 Interfaces

Connector pin
allocation X7.1/
X7.2

Fig. 6-3: Connector pin allocation X7.1 and X7.2

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 21 / 55

 Drive Box for External Axes

Connector pin
allocation X28

Fig. 6-4: Connector pin allocation X28

Connector pin
allocation X29

Fig. 6-5: Connector pin allocation X29

22 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 6 Planning

6.6 Options for controlling the external axes

Drive box 1x12

Fig. 6-6: Option, drive box 1x12

1 KR C4 compact robot controller

2 Data cable, robot controller KR C4 compact X28 – drive box X29
3 Drive box
4 Motor, external axis 1
5 Motor cable, external axis 1
6 Resolver cable, external axis 1
7 Manipulator

Drive box 2x12

Fig. 6-7: Option, drive box 2x12

1 KR C4 compact robot controller

2 Data cable, robot controller KR C4 compact X28 – drive box X29
3 Drive box
4 Motor, external axis 2
5 Motor cable, external axis 2
6 Resolver cable, external axis 2
7 Motor, external axis 1
8 Motor cable, external axis 1
9 Resolver cable, external axis 1
10 Manipulator

Drive box 1x12+ With this option – drive box 1x12+ combined with drive box 1x12 – the brakes
and 1x12 for the external axes can be controlled individually.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 23 / 55

 Drive Box for External Axes

Fig. 6-8: Option, drive box 1x12+ combined with drive box 1x12

1 KR C4 compact robot controller

2 Data cable, robot controller KR C4 compact X28 – drive box 1 X29
3 Data cable, drive box 1 X28 – drive box 2 X29
4 Drive box 1
5 Drive box 2
6 Motor, external axis 1
7 Motor cable, external axis 1
8 Resolver cable, external axis 1
9 Motor, external axis 2
10 Motor cable, external axis 2
11 Resolver cable, external axis 2
12 Manipulator

6.7 PE equipotential bonding

Description The following cables must be connected before start-up:

 A 4 mm2 cable as equipotential bonding between the manipulator and the

robot controller.
 A 4 mm2 cable as equipotential bonding between the drive box and the ro-
bot controller.
 An additional PE conductor between the central PE rail of the supply cab-
inet and the PE connection of the robot controller. A cross section of
4 mm2 is recommended.

24 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 6 Planning

Fig. 6-9: Equipotential bonding

1 Equipotential bonding connection on the manipulator

2 PE cable between the manipulator and the robot controller
3 PE cable to the central PE rail of the supply cabinet
4 Equipotential bonding connections on the robot controller
5 PE cable between the drive box and the robot controller
6 Equipotential bonding connections on the drive box

6.8 Performance level

The safety functions of the robot controller conform to category 3 and Perfor-
mance Level d according to EN ISO 13849-1.

6.8.1 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 E-STOP device
is tested at least once every 6 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 systems 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 controller
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
 Safety functions of KUKA.SafeOperation (option)
 Monitoring of axis spaces
 Monitoring of Cartesian spaces
 Monitoring of axis velocity

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 25 / 55

 Drive Box for External Axes

 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 compact with drive box for external axes < 1 x 10-7

For controller variants that are not listed here, please contact KUKA
Roboter GmbH.

26 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 7 Transportation

7 Transportation

7.1 Transporting the drive box

Preconditions  The housing of the drive box must be closed.

 No cables may be connected to the drive box.
 The drive box must be transported in a horizontal position.

Procedure  Transport the drive box on a trolley.

Fig. 7-1: Transportation with trolley

7.2 Transportation without trolley

Preconditions  The housing of the drive box must be closed.

 No cables may be connected to the drive box.

Procedure  Transport the drive box using the carrying handles.

Fig. 7-2: Transportation without trolley

1 Carrying handles

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 27 / 55

 Drive Box for External Axes

28 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 8 Start-up and recommissioning

8 Start-up and recommissioning

8.1 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 circum-
stances.
For this reason, the overview does not claim to be comprehensive.

This overview refers to the start-up of the industrial robot with external
axes. The start-up of the overall system is not within the scope of this
documentation.

Electrical system

Step Description Information

1 Installing the drive box (>>> 8.2 "Installing the drive box"
Page 29)
2 Connecting the connecting cables (>>> 8.3 "Connecting the connecting
cables" Page 29)
3 Connecting the equipotential bonding (>>> 8.4 "Connecting the PE equipo-
on the drive box tential bonding" Page 30)
4 Connecting the drive box to the power (>>> 8.5 "Connecting the drive box to
supply the power supply" Page 30)
5 Switching the robot controller on (>>> 8.6 "Switching on the robot con-
troller with the drive box" Page 30)

8.2 Installing the drive box

Procedure 1. Install the drive box. The minimum clearances to walls, other cabinets, etc.
must be observed. (>>> 6.2 "Installation conditions" Page 19)
2. Check the drive box for any damage caused during transportation.
3. Check that fuses, contactors and boards are fitted securely.
4. Secure any modules that have come loose.
5. Check that all screwed and clamped connections are securely fastened.
6. Only install the drive box horizontally.

8.3 Connecting the connecting cables

Overview The following cables are required depending on the control option and instal-
lation site:
 Motor cable for external axes
 Resolver cable for external axes
 Data cable for drive box
 PE cables for drive box

Procedure 1. Connect data cable X29 on the drive box to interface X28 on the KR C4
compact.
2. Connect data cable X29 on drive box 2 to interface X28 on drive box 1.
3. Connect motor connector X7.1 on drive box 1 to external axis 1.
4. Connect motor connector X7.2 on drive box 1 to external axis 2.
If a drive box 2 is available:

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 29 / 55

 Drive Box for External Axes

Connect motor connector X7.1 on drive box 2 to external axis 2.

5. Connect the resolver cable for the external axes to the manipulator.

8.4 Connecting the PE equipotential bonding

Procedure 1. With a 4 mm2 cable as equipotential bonding, connect the drive box to the
KR C4 compact robot controller.
2. Carry out a ground conductor check for the entire robot system in accor-
dance with DIN EN 60204-1.

8.5 Connecting the drive box to the power supply

8.5.1 Connecting the drive box to the power supply with mains connector

Precondition  The drive box is switched off.

 The power cable is de-energized.

Procedure 1. On the drive box, plug in the connector for non-heating appliances for the
device connection cable.
2. Connect the drive box to the mains via the mains connector.

8.5.2 Connecting the drive box to the power supply without mains connector

Precondition  The drive box is switched off.

 The power cable is de-energized.
 Connection to the power supply must be carried out in accordance with the
applicable national regulations.
 The power supply connection and the mains connector must be designed
in accordance with the performance data of the drive box. (>>> "Power
supply connection" Page 13)
1. On the drive box, plug in the connector for non-heating appliances for the
device connection cable.
2. Connect the drive box to the mains via the mains connector.
3. Connect the drive box to a grounded-neutral power supply system.
 Green/yellow (GNYE) to the PE of the power supply system
 Light blue (BU) to the neutral conductor of the power supply system
 Black (BK) to the live cable of the power supply system

Fig. 8-1: Power supply connection

8.6 Switching on the robot controller with the drive box

Preconditions  The manipulator has been installed in accordance with the operating in-
structions.

30 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 8 Start-up and recommissioning

 All electrical connections are correct and the energy levels are within the
specified limits.
 The housings of the robot controller and drive box are closed.
 The peripheral devices are correctly connected.
 It must be ensured that no persons or objects are present within the dan-
ger zone of the manipulator and the external axes.
 All safety devices and protective measures are complete and fully func-
tional.
 The internal temperature of the robot controller and the drive box must
have adapted to the ambient temperature.

Procedure 1. Release the EMERGENCY STOP device on the smartPAD.

2. Switch on the main switch.
The control PC begins to run up (load) the operating system and the con-
trol 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.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 31 / 55

 Drive Box for External Axes

32 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 9 Maintenance

9 Maintenance
Description Maintenance work must be performed at the specified maintenance intervals
after commissioning at the customer’s plant.

9.1 Maintenance symbols

Maintenance
symbols
Oil change

Lubricate with grease gun

Lubricate with brush

Tighten screw/nut

Check component, visual inspection

Clean component

Exchange battery

Precondition  The robot controller and drive box must be switched off and secured to
prevent unauthorized persons from switching them on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...600 V) up to 5 minutes after the drive box has been
switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for external axis connectors X7.1/X7.2 and connected ca-
bles
This voltage can cause life-threatening injuries.

Fig. 9-1: Maintenance points

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 33 / 55

 Drive Box for External Axes

Interval Item Activity

1 year at 1 Depending on installation conditions and degree of
the latest fouling, clean the protective grille and the fan with a
brush.
5 years 1 Exchange the drive box fans
(with 3-shift
operation)

Once an activity from the maintenance list has been carried out, a visual in-
spection must be made, with special attention to the following points:
 Check that fuses, contactors, plug-in connections and boards are fitted se-
curely.
 Damage to cabling.
 Check PE equipotential bonding connection.
 Wear and damage to any system components.

9.2 Cleaning the drive box

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.

Work regulations  The manufacturer’s instructions must be observed when using cleaning
agents for cleaning work.
 It must be ensured that no cleaning agents enter electrical components.
 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 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.

34 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 10 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 sup-
port personnel or by customers who have taken part in a relevant course of
training held by KUKA Roboter GmbH.
Repairs within modules may only be carried out by specially trained KUKA Ro-
boter GmbH personnel.

Procurement of The article numbers of the spare parts are listed in the spare parts catalog.
spare parts KUKA Roboter 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 Roboter GmbH.

A “Robot Repair Card” is supplied with the exchange parts. The Re-
pair Card must be completed and returned to KUKA Roboter GmbH.

10.2 Exchanging the drive box fans

Precondition  The robot controller and drive box must be switched off and secured to
prevent unauthorized persons from switching them on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...600 V) up to 5 minutes after the drive box has been
switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for external axis connectors X7.1/X7.2 and connected ca-
bles
This voltage can cause life-threatening injuries.

Procedure 1. Unscrew the housing cover screws and open the cover.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 35 / 55

 Drive Box for External Axes

Fig. 10-1: Opening the housing cover

1 Housing cover screws

2. Remove the fastening screws from the fan holder.

Fig. 10-2: Fastening of fans

1 Fastening of the fan holder

3. Remove the cable straps from the connecting cables for the fans and re-
move the fan holder with the fans.
4. Unplug the fan connections.

Fig. 10-3: Connection for fans

1 Connector for fans

2 Cable straps

5. Unscrew the fans and fan grilles.

6. Fasten the new fans and fan grilles to the fan holder and secure the con-
necting cables with cable straps.
7. Plug in the connecting cables.
8. Install the fan holder with the new fans.

36 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 10 Repair

10.3 Exchanging the mains filter

Precondition  The robot controller and drive box must be switched off and secured to
prevent unauthorized persons from switching them on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...600 V) up to 5 minutes after the drive box has been
switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for external axis connectors X7.1/X7.2 and connected ca-
bles
This voltage can cause life-threatening injuries.

Procedure 1. Unscrew the housing cover screws and open the cover.

Fig. 10-4: Opening the housing cover

1 Housing cover screws

2. Remove the fastener for the plug-in connector with mains filter.
3. Push the plug-in connector with mains filter forward through the opening.
4. Remove the mains filter fastener.
5. Disconnect the mains filter connections and remove mains filter from the
drive box.

Fig. 10-5: Mains filter fastener

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 37 / 55

 Drive Box for External Axes

1 Fastener, plug-in connector with mains filter

2 Connections, plug-in connector with mains filter
3 Connections, mains filter
4 Fastener, mains filter
5 Plug-in connector with mains filter

6. Install the new mains filter.

7. Install the plug-in connector with mains filter.

10.4 Exchanging the brake resistor

Precondition  The robot controller and drive box must be switched off and secured to
prevent unauthorized persons from switching them on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...600 V) up to 5 minutes after the drive box has been
switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for external axis connectors X7.1/X7.2 and connected ca-
bles
This voltage can cause life-threatening injuries.

Procedure 1. Unscrew the housing cover screws and open the housing cover.

Fig. 10-6: Opening the housing cover

1 Housing cover screws

2. Remove the fastening screws from the brake resistor.

3. Unplug the brake resistor connections.

38 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 10 Repair

Fig. 10-7: Brake resistor fastening

1 Fastening screws on brake resistor

2 Brake resistor connection
3 Cable strap

4. Remove the brake resistor from the drive box.

5. Install the new brake resistor.
6. Connect the brake resistor in accordance with the cable labeling and and
circuit diagram and secure with cable straps

10.5 Replacing the contactor

Precondition  The robot controller and drive box must be switched off and secured to
prevent unauthorized persons from switching them on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...600 V) up to 5 minutes after the drive box has been
switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for external axis connectors X7.1/X7.2 and connected ca-
bles
This voltage can cause life-threatening injuries.

Procedure 1. Unscrew the housing cover screws and open the cover.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 39 / 55

 Drive Box for External Axes

Fig. 10-8: Opening the housing cover

1 Housing cover screws

2. Detach all connections from the contactor.

3. Remove the contactor from the top-hat rail.

Fig. 10-9: Contactor

1 Contactor

4. Fasten the new contactor to the top-hat rail.

5. Connect all connections on the contactor in accordance with the cable la-
beling and circuit diagram.

10.6 Exchanging the KPP_SR

Precondition  The robot controller and drive box must be switched off and secured to
prevent unauthorized persons from switching them on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...600 V) up to 5 minutes after the drive box has been
switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for external axis connectors X7.1/X7.2 and connected ca-
bles
This voltage can cause life-threatening injuries.

Procedure 1. Unscrew the housing cover screws and open the cover.

40 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 10 Repair

Fig. 10-10: Opening the housing cover

1 Housing cover screws

2. Unplug the connections on the KPP_SR.

3. Remove the fastening screws of the KPP_SR board.

Fig. 10-11: Fastening the KPP_SR

1 Fastening screws on the KPP_SR

4. Remove the KPP_SR.

5. Install and fasten the new KPP_SR.
6. Plug in all the connections in accordance with the connector and cable la-
beling.
7. Close the housing cover.

10.7 Exchanging the KSP_SR

Precondition  The robot controller and drive box must be switched off and secured to
prevent unauthorized persons from switching them on again.
 The power cable is disconnected from the drive box.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 41 / 55

 Drive Box for External Axes

The following components may remain energized

(50...600 V) up to 5 minutes after the drive box has been
switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for external axis connectors X7.1/X7.2 and connected ca-
bles
This voltage can cause life-threatening injuries.

Procedure 1. Unscrew the housing cover screws and open the cover.

Fig. 10-12: Opening the housing cover

1 Housing cover screws

2. Unplug the connections on the KSP_SR.

3. Remove the fastening screws from the KSP_SR heat sink.

Fig. 10-13: Fastening the KSP_SR

1 Fastening screws on the KSP_SR heat sink

4. Remove the KSP_SR together with the heat sink.

5. Install and fasten the new KSP_SR.
6. Plug in all the connections in accordance with the connector and cable la-
beling.
7. Close the housing cover.

42 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 11 Decommissioning, storage and disposal

11 Decommissioning, storage and disposal

11.1 Decommissioning

Description This section describes all the work required for decommissioning the drive box
if the drive box is to be removed from the system. After decommissioning, it is
prepared for storage or for transportation to a different location.
Following its removal, the drive box may only be transported on a trolley, with
a fork lift truck or pallet truck.

Precondition  The removal site is accessible for transportation with a trolley.

 The trolley has sufficient load-bearing capacity.
 There is no hazard posed by system components.

Procedure 1. Unplug the mains connector.

2. Release and unplug the motor cable and control cable connectors.
3. Remove the ground conductor.
4. Prepare the drive box for storage.

11.2 Storage

Preconditions If the drive box 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 storage.
 Select a storage location in which the packaging materials cannot be dam-
aged.
 Only store the drive box indoors.

Procedure 1. Clean the drive box. No dirt may remain on or in the drive box.
2. Inspect the drive box, both internally and externally, for damage.
3. Remove any foreign bodies.
4. Remove any corrosion expertly.
5. Attach all covers to the drive box and check that the seals are correctly in
place.
6. Seal off electrical connections with suitable covers.
7. Cover the drive box with plastic film and seal it against dust.
If necessary, add a desiccant beneath the sheeting.

11.3 Disposal

When the drive box reaches the end of its useful life, it can be dismantled, and
the materials can be disposed of properly by type.
The following table provides an overview of the materials used in the robot
controller. Some of the plastic components are marked with a material desig-
nation and must be disposed of accordingly.

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 43 / 55

 Drive Box for External Axes

Material, designation Subassembly, compo- Remark

nent
Steel-plate compo- Screws and washers, -
nents robot controller hous-
ing
PUR Cable sheaths -
Plastic parts Flexible tube -
Cable Electrical cables, -
wires, copper
EPDM Seals and covers -
CuZn (gold-plated) Connectors, contacts Dispose of without dis-
mantling
Steel (ST 52-3) Allen screws, washers -
PE Cable straps -
Electrical components Bus modules, boards, Dispose of as electri-
sensors cal scrap without dis-
assembling
Mains filter
Fans
Adhesive labels

44 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 12 KUKA Service

12 KUKA Service

12.1 Requesting support

Introduction This documentation provides information on operation and operator control,

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

Information The following information is required for processing a support request:

 Model and serial number of the manipulator
 Model and serial number of the controller
 Model and serial number of the linear unit (if present)
 Model and serial number of the energy supply system (if present)
 Version of the system software
 Optional software or modifications
 Diagnostic package KrcDiag:
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the soft-
ware (KrcDiag is not yet available here.)
 Application used
 External axes used
 Description of the problem, duration and frequency of the fault

12.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)

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

Australia KUKA Robotics Australia Pty Ltd

45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
[email protected]
www.kuka-robotics.com.au

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 45 / 55

 Drive Box for External Axes

Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China KUKA Robotics China Co., Ltd.

No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
[email protected]
www.kuka-robotics.com

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
[email protected]
www.kuka-roboter.de

46 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 12 KUKA Service

France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr

India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
[email protected]
www.kuka.in

Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
[email protected]
www.kuka.it

Japan KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
[email protected]

Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 47 / 55

 Drive Box for External Axes

Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
[email protected]

Malaysia KUKA Robot Automation (M) Sdn Bhd

South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
[email protected]

Mexico KUKA de México S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]
www.kuka-robotics.com/mexico

Norway KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
[email protected]

Austria KUKA Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
[email protected]
www.kuka.at

48 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 12 KUKA Service

Poland KUKA Roboter Austria GmbH

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]

Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
[email protected]

Russia KUKA Robotics RUS

Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
[email protected]
www.kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 49 / 55

 Drive Box for External Axes

Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
[email protected]
www.kuka-e.com

South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
[email protected]
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
[email protected]
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
[email protected]

50 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 12 KUKA Service

Hungary KUKA Robotics Hungaria Kft.

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

USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com

UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
[email protected]

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 51 / 55

 Drive Box for External Axes

52 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 Index

Index
A M
Accessories 9 Mains filter, exchanging 37
Altitude 13 Maintenance 33
Ambient temperature 13 Maintenance symbols 33
Manipulator 5, 9
B Material designation 43
Basic data 13 Minimum clearances 14
Brake resistor, exchanging 38 Motor cable, external axes 10

C O
Cable lengths 14 Options 9
Connecting cables 9, 29 Overview, start-up 29
Connection conditions 20
Contactor, exchange 39 P
Cooling 11 PE equipotential bonding 24
Cooling circuit 11 PE equipotential bonding, connection 30
Performance level 25
D PFH values 25
Data cable, drive box 10 PL 25
Decommissioning 43 Planning 19
Description of the industrial robot 9 Plates and labels 15
Device connection cable 10 Power supply connection 21
Dimensions 14 Power supply, connection 30
Dimensions, handle brackets 15 Procurement of spare parts 35
Disposal 43 Product description 9
Drive box 9 Purpose 7
Drive box fans, exchange 35
Drive box, cleaning 34 R
Drive box, installation 29 Recommissioning 29
Drive box, overview 9 Repair 35
Robot controller 9
E Robot controller, switching on 30
Electromagnetic compatibility, EMC 19
EMC 5 S
Environmental conditions 13 Safety 17
External axes 9 Safety instructions 5
Service, KUKA Roboter 45
F Socket for non-heating appliances 21
Filter mats 11 Software 9
Fusing 21 Start-up 29
Start-up overview 29
H Storage 43
Humidity class 13 Support request 45

I T
Industrial robot 9 Target group 7
Infeed 21 Teach pendant 9
Installation conditions 19 Technical data 13
Intended use 7 Terms used 5
Interfaces 10, 21 Training 7
Introduction 5 Transportation 27
Transportation without trolley 27
K
KPP_SR 5 V
KPP_SR, exchange 40 Vibration resistance 13
KSP_SR 5
KSP_SR, exchange 41 W
KUKA Customer Support 45 Warnings 5

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 53 / 55

 Drive Box for External Axes

X
X28 Connector pin allocation 22
X29 Connector pin allocation 22
X7.1/X7.2, connector pin allocation 21

54 / 55 Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3

 Drive Box for External Axes

Issued: 28.08.2014 Version: MA external axis box KR C4 compact V3 55 / 55