2. Technical Specifications

• Model: KRC4 (compact/smallsize‑2/standard/midsize/extended)

• Controller Type: Multi‑core PC‑based, real‑time Linux, integrated PLC/safetyKUKA

• Compatible Robots: KR QUANTEC, KR CYBERTECH, KR CYBERTECH‑2, KR IONTECK, KR QUANTEC nano

• System Software: KSS V8.x / V9.x (Linux‑based)

• Power Supply: 3×208/400/415/480/575 V AC, 49–61 Hz, 25–32 A

• Standard Interfaces: Ethernet (10/100/1000 Mbps), CANopen, USB 2.0, RS‑232

• Optional Fieldbuses: PROFINET, EtherCAT, PROFIBUS, DeviceNet

• Drives: Integrated digital servo drives for 6 robot axes + up to 3 external axesmyKUKA

• Teach Pendant: smartPAD (10.1” touchscreen, 6D joystick, IP65)

• Protection Class: IP54 (cabinet), IP65 (smartPAD front)myKUKA

• Operating Temp: +5°C to +45°CmyKUKA

• Storage Temp: -20°C to +60°C

• Dimensions (W×H×D):

  • Compact: ~400×500×300 mm

  • Standard: ~792×960×602 mmmyKUKA

• Weight: 33–240 kg (varies by model)KUKA

3. Main Components & Controls

3.1 Control Cabinet

• Main Power Switch: 3‑phase AC input ON/OFF.

• Emergency Stop (E‑Stop): Red mushroom button; dual‑channel safety cuts servo power.

• Reset Button: Clears faults, resets safety, restarts system.

• Status LEDs: Power (green), Run (green blinking), Error (red), Servo Ready (yellow).

• Control PC: Multi‑core CPU, 1 GB RAM, 16 GB flash memory.

• Safety Controller: Integrated dual‑channel safety (EN ISO 13849‑1 Cat. 4).

• Servo Drives: Integrated for axes 1–6 + up to 3 external axesmyKUKA.

• I/O Module: 64 digital / 32 analog (expandable).

• Fieldbus Slots: PROFINET, EtherCAT, PROFIBUS options.

• USB/Ethernet: For program backup/restore, WorkVisual connection.

3.2 Teach Pendant (smartPAD)

• 10.1” TFT Touchscreen: 1280×800 resolution, color display.

• 6D Joystick: Cartesian (X/Y/Z/A/B/C) or axis‑specific (A1–A6) jogging.

• 3‑Position Enabling Switch (Rear):

  • 0: Disabled (no motion)

  • 1: Enabled (manual jog; must be held)

  • 2: Disabled (no motion)

• Mode Switch:

  • T1: Manual low speed (≤250 mm/s; teaching)

  • T2: Manual high speed (verification)

  • AUT: Automatic mode (production)

  • EXT: External PLC control

• Alphanumeric Keypad: Program editing, data input.

• Function/Softkeys: Menu navigation, command selection (e.g., PTP, LIN, CIRC).

• Touchscreen: Direct menu access, program editing, diagnostics.

4. Safety Instructions

• E‑Stop: Use only in emergencies; stops all servo motion via dual‑channel safety.

• Enabling Switch: Must be held in Position 1 for manual jog; robot stops if released.

• Mode Rules:

  • T1: Reduced speed; use for teaching/testing.

  • T2: High speed; ensure workspace is clear.

  • AUT: No personnel in workspace; safety doors closed.

  • EXT: External PLC control; safety interlocks required.

• Integrated Safety: Dual‑channel safety controller monitors E‑stop, enabling switch, safety doors, and axis limits (Cat. 4, PL d).

• No Modification: Never bypass or modify safety circuits (E‑Stop, safety controller, enabling switch).

• Work Envelope: Stay clear of robot’s full range of motion.

5. Installation & Connection

1. Positioning: Place cabinet on flat, level floor; allow 100 mm clearance for ventilation.

2. Power Connection: Connect 3‑phase AC to X1; ensure correct voltage (400 V AC standard).

3. Motor Cables: Connect axes 1–6 motors to X20; tighten connectors.

4. smartPAD Connection: Connect smartPAD cable to KCP port; lock connector.

5. Fieldbus Setup: Install PROFINET/EtherCAT/Ethernet cables; configure addresses.

6. I/O Wiring: Connect 24 V DC I/O to terminal blocks; check polarity.

7. Grounding: Earth cabinet and robot base per local codes.

8. WorkVisual: Connect PC via Ethernet for configuration, programming, and diagnostics.

6. Operating Instructions

6.1 Power‑Up

1. Turn main power switch ON.

2. System boots Linux real‑time OS and KSS V8.x/V9.x.

3. Check LEDs: Power ON, Run blinking, Error OFF.

4. Press Reset to clear faults and reset safety.

5. Switch to T1 mode; hold enabling switch (Position 1).

6. Jog robot to verify motion.

6.2 Manual Jogging (T1/T2)

1. Mode: T1 (low speed) or T2 (high speed).

2. Hold enabling switch in Position 1.

3. Joystick:

   • Axis Mode: Move individual joints (A1–A6).

   • Cartesian Mode: Move TCP in X/Y/Z; rotate A/B/C.

4. Adjust speed with HOV (Handwheel Override) keys (0–100%).

6.3 Programming (T1)

1. T1 mode; enable switch held.

2. Jog to desired position; press Record to store.

3. Add commands:

   • PTP: Point‑to‑point motion

   • LIN: Linear motion

   • CIRC: Circular motion

   • WAIT: Pause

   • IF/FOR: Logic control

   • SPS: Integrated PLC commands

4. Name program; save to flash or USB.

5. Use WorkVisual for offline programming and simulation.

6.4 Automatic Operation (AUT)

1. Select program from list.

2. Mode: AUT.

3. Clear workspace; close safety doors.

4. Press Start on smartPAD or external panel.

5. Press Stop to pause; E‑Stop for emergency.

6.5 External Operation (EXT)

1. Connect external PLC via PROFINET/EtherCAT/Ethernet.

2. Configure I/O signals for Start/Stop, Fault Reset, Program Select.

3. Mode: EXT; ensure safety interlocks are closed.

4. Control robot via PLC commands.

7. Maintenance

• Daily: Check E‑Stop function; inspect cables for damage.

• Weekly: Clean cabinet filters; verify fan operation.

• Monthly: Check servo drive temperatures; tighten connectors.

• Quarterly: Backup programs to USB; test restore.

• Annual: Replace battery (CMOS/encoder); calibrate smartPAD touchscreen.

• Environment: Keep cabinet dry; avoid dust and vibration.