Kuka Sunrise Cabinet Med User manual

Controller
KUKA Sunrise Cabinet Med
Instructions for Use
Issued: 26.11.2021
GA KUKA Sunrise Cabinet Med V5
KUKA Deutschland GmbH

KUKA Sunrise Cabinet Med
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© Copyright 2021
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 GA KUKA Sunrise Cabinet Med (PDF) en
PB8035
Book structure: GA KUKA Sunrise Cabinet Med V5.1
BS7388
Version: GA KUKA Sunrise Cabinet Med V5

Contents
1 Introduction.............................................................................................. 7
1.1 LBR Med documentation....................................................................................... 7
1.2 Target group.......................................................................................................... 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Trademarks............................................................................................................ 8
1.5 Terms used............................................................................................................ 8
2 Product description................................................................................. 13
2.1 Overview of the robot system............................................................................... 13
2.2 KUKA Sunrise Cabinet Med................................................................................. 14
2.3 Control PC............................................................................................................. 15
2.4 Cabinet Control Unit, Small Robot....................................................................... 15
2.5 Low-voltage power supply..................................................................................... 16
2.6 Batteries................................................................................................................. 16
2.7 Description of interfaces........................................................................................ 16
2.7.1 Motherboard D3445-K PC interfaces.................................................................... 17
2.8 Cooling................................................................................................................... 18
2.9 Intended use.......................................................................................................... 18
3 Safety......................................................................................................... 21
3.1 General.................................................................................................................. 21
3.1.1 Disclaimer.............................................................................................................. 21
3.1.1.1 CB Test Certificate and CB Test Report.............................................................. 22
3.1.1.2 EC declaration of conformity and declaration of incorporation............................ 22
3.1.2 Terms in the “Safety” chapter............................................................................... 23
3.2 Groups of persons................................................................................................. 25
3.3 Workspace, safety zone and danger zone........................................................... 26
3.4 Triggers for safety-oriented stop reactions........................................................... 27
3.5 Safety functions..................................................................................................... 28
3.5.1 Safety-oriented functions....................................................................................... 29
3.5.1.1 EMERGENCY STOP device................................................................................. 30
3.5.1.2 Enabling device..................................................................................................... 30
3.5.1.3 “Operator safety” signal......................................................................................... 31
3.5.1.4 External EMERGENCY STOP device.................................................................. 32
3.5.1.5 External safety stop 1 (path-maintaining) ........................................................... 32
3.5.1.6 External enabling device....................................................................................... 32
3.5.1.7 External safe operational stop.............................................................................. 32
3.5.2 Non-safety-oriented functions................................................................................ 33
3.5.2.1 Mode selection...................................................................................................... 33
3.5.2.2 Velocity monitoring in T1....................................................................................... 34
3.5.2.3 Software limit switches.......................................................................................... 34
3.6 Service phases of the robot system..................................................................... 34
3.7 Additional protective equipment............................................................................ 35
3.7.1 Jog mode............................................................................................................... 35
3.7.2 Labeling on the LBR Med..................................................................................... 35
3.7.3 External safeguards............................................................................................... 35
3.8 Safety measures.................................................................................................... 36
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3.8.1 General safety measures...................................................................................... 36
3.8.2 IT security.............................................................................................................. 38
3.8.3 Transportation........................................................................................................ 38
3.8.4 Start-up and recommissioning.............................................................................. 39
3.8.5 Manual mode......................................................................................................... 41
3.8.6 Automatic mode..................................................................................................... 42
3.8.7 Maintenance and repair........................................................................................ 42
3.8.8 Decommissioning, storage and disposal.............................................................. 44
3.8.9 Safety measures for “single point of control”....................................................... 44
3.9 Risk management.................................................................................................. 44
4 Technical data.......................................................................................... 49
4.1 Cabinet Interface Board, Small Robot.................................................................. 51
4.2 Dimensions............................................................................................................ 52
4.3 Dimensions of handle brackets............................................................................. 53
4.4 Dimensions of the smartPAD holder (optional).................................................... 53
4.5 Plates and labels................................................................................................... 54
4.6 REACH duty to communicate information acc. to Art. 33 of Regulation (EC)
1907/2006.............................................................................................................. 55
5 Planning.................................................................................................... 57
5.1 Overview................................................................................................................ 57
5.2 Electromagnetic compatibility (EMC).................................................................... 57
5.3 Installation conditions............................................................................................ 58
5.4 Connection conditions........................................................................................... 59
5.5 Power supply connection...................................................................................... 60
5.6 Interface and connector pin allocation.................................................................. 60
5.6.1 Interface X11......................................................................................................... 61
5.6.1.1 Contact diagram, connector X11.......................................................................... 61
5.6.1.2 X11 safety interface............................................................................................... 62
5.6.1.3 Wiring example for E-STOP circuit and safeguard.............................................. 63
5.6.1.4 Wiring example for safe inputs and outputs........................................................ 64
5.6.2 KUKA Extension Bus X65..................................................................................... 66
5.6.3 KUKA Line Interface X66...................................................................................... 67
5.6.4 X69 KUKA Service Interface................................................................................. 68
5.6.5 X55 External power supply (optional)................................................................... 69
5.6.6 PE equipotential bonding...................................................................................... 70
6 Transportation.......................................................................................... 71
6.1 Transportation by trolley........................................................................................ 71
6.2 Transportation without trolley................................................................................ 71
7 Start-up and recommissioning............................................................... 73
7.1 Overview................................................................................................................ 73
7.2 Installing the robot controller................................................................................. 74
7.3 Connecting the connecting cables........................................................................ 74
7.4 Plugging in the KUKA smartPAD.......................................................................... 75
7.5 Connecting the PE equipotential bonding............................................................ 75
7.6 Reversing the battery discharge protection measures......................................... 75
7.7 Configuring and connecting connector X11.......................................................... 76
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7.8 Connecting the robot controller to the power supply........................................... 76
7.8.1 Connecting the robot controller to the power supply with a mains connector.... 76
7.8.2 Connecting the robot controller to the power supply without a mains connec-
tor........................................................................................................................... 77
7.9 Switching on the robot controller.......................................................................... 77
8 Operation.................................................................................................. 79
8.1 KUKA smartPAD teach pendant........................................................................... 79
8.1.1 smartPAD............................................................................................................... 79
8.1.1.1 Front view.............................................................................................................. 79
8.1.1.2 Rear view............................................................................................................... 82
8.1.2 smartPAD-2............................................................................................................ 83
8.1.3 Disconnecting and connecting the smartPAD...................................................... 83
9 Maintenance.............................................................................................. 85
9.1 Checking CCU_SR relay outputs......................................................................... 86
9.2 Cleaning the robot controller................................................................................. 87
10 Repair........................................................................................................ 89
10.1 Repair and procurement of spare parts............................................................... 89
10.2 Opening the housing cover................................................................................... 89
10.3 Exchanging the motherboard battery.................................................................... 90
10.4 Exchanging the hard drive.................................................................................... 91
10.5 Exchanging the batteries....................................................................................... 92
10.6 Exchanging the fans.............................................................................................. 94
10.7 Installation of KUKA Sunrise.OS Med.................................................................. 95
11 Troubleshooting....................................................................................... 97
11.1 LED display on Cabinet Control Unit, Small Robot............................................. 97
11.2 Fuses on the Cabinet Control Unit, Small Robot................................................ 101
11.3 Power supply connection fuses............................................................................ 103
11.4 Fuse, DC/DC converter......................................................................................... 103
11.5 Low-voltage power supply unit fuses................................................................... 104
12 Decommissioning, storage and disposal............................................. 105
12.1 Decommissioning................................................................................................... 105
12.2 Storage.................................................................................................................. 105
12.3 Disposal................................................................................................................. 105
13 Appendix................................................................................................... 107
13.1 Applied standards and directives.......................................................................... 107
14 KUKA Service........................................................................................... 109
14.1 Requesting support............................................................................................... 109
14.2 KUKA Customer Support...................................................................................... 109
Index 111
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1 Introduction
1.1 LBR Med documentation
The documentation consists of the following parts:
• Instructions for Use of LBR Med:
Instructions for Use of LBR Med 7 R800 and LBR Med 14 R820
• Instructions for Use of KUKA Sunrise Cabinet Med:
Information about operating the robot controller
• Documentation for the smartPAD-2 (if used)
• Instructions for Use of KUKA Sunrise.OS Med:
Operating and Programming Instructions for System Integrators
• Instructions for options and accessories
• Spare parts in KUKA.Xpert
Each set of instructions is a separate document.
For integration of the LBR Med into a medical product, additionally sup-
plied documents are available to the medical product manufacturer,
which must be taken into consideration.
(>>> 13 "Appendix" Page 107)
1.2 Target group
This documentation is aimed at medical product manufacturers. The medi-
cal product manufacturer must ensure that the LBR Med is only handled
by appropriately trained skilled personnel with the following knowledge
and skills:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical engineering
• Knowledge of the robot controller system
This documentation may not be forwarded to the medical product manu-
facturer’s customer as Instructions for Use.
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.
1.3 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.
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Introduction

CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.
These warnings contain references to safety-relevant information or gen-
eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.
This warning draws attention to procedures which serve to prevent or rem-
edy emergencies or malfunctions:
SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
Notices
These notices serve to make your work easier or contain references to
further information.
Tip to make your work easier or reference to further information.
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.
1.5 Terms used
Term Description
B Body
BF Body Floating
CBTC Certified body test certification:
CB Test Certificate
CBTR Certified body test report:
CB Test Report
CCU_SR Cabinet Control Unit, Small Robot
CF Cardial Floating
CIB_SR Cabinet Interface Board, Small Robot
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Drape Sterile sleeve in medicine for covering non-sterile devices or com-
ponents.
Dual NIC Dual Network Interface Card
Dual-port network card
EDS Electronic Data Storage
(memory card)
EMC Electromagnetic compatibility
End user Customer of the medical device manufacturer (user, e.g. medical
personnel)
Main switch The term “main switch” used in this documentation refers to a de-
vice switch as defined by relevant standards, as it has no grid iso-
lation function.
KCB KUKA Controller Bus
KEI KUKA EtherCAT Interface
KLI KUKA Line Interface
Ethernet interface of the robot controller for external communica-
tion.
KOI KUKA Operator Panel Interface
KONI KUKA Option Network Interface
Interface for KUKA options
KSB KUKA System Bus
Field bus for internal networking of the controllers
KSI KUKA Service Interface
Interface on the CSP on the control cabinet or robot controller
The WorkVisual PC can either connect to the robot controller via
the KLI or it can be plugged into the KSI.
KSS KUKA System Software
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
KUKA Sunrise
Cabinet
Control hardware for operating robots. Hereinafter called “robot con-
troller” in these Instructions for Use.
KUKA Sunrise.OS KUKA Sunrise.Operating System
System Software for robots which are operated with the robot con-
troller KUKA Sunrise Cabinet
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Introduction

LBR Lightweight robot
Robot as part of a robotic component
There are 2 robot variants available:
• LBR Med 7 R800
• LBR Med 14 R820
Hereinafter called “robot” for both variants in these Instructions for
Use.
LBR Med A robotic component for integration into a medical device by a
medical device manufacturer. The LBR Med includes all assem-
blies, such as the robot (robot arm and the associated electrical in-
stallations), robot controller and connecting cables.
Hereinafter also called “robot system” in these Instructions for Use.
Med Identifier for KUKA products that are supplied to medical device
manufacturers.
ME sytems Medical electrical systems
ME devices Medical electrical devices
MOOP Means of Operator Protection: measure for operator protection
Protective measure that is intended to reduce the risk to the opera-
tor of an electric shock.
MOP Means of Protection: safety measure
Measures for reducing the risk of an electric shock acc. to IEC
60601-1. Umbrella term for MOOP and MOPP.
MOPP Means of Patient Protection: measure for patient protection
Protective measure that is intended to reduce the risk to the patient
of an electric shock.
Medical device manufac-
turer
(distributor, customer)
The customer is the manufacturer of the medical device. In their
capacity as medical device manufacturer/system integrator, they in-
tegrate the robotic component into their medical device and market
the overall system as a medical device.
System integrator
(plant integrator)
System integrators are people who safely integrate the LBR Med
into a medical device and commission it.
End user Customer of the medical device manufacturer (user, e.g. medical
personnel)
PDS Power Drive System
PMB_SR Power Management Board, Small Robot
SATA connections Data bus for exchanging data between the processor and the hard
drive
Transmission request signal
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smartPAD Teach pendant
The smartPAD is the teach pendant for the robot. It provides all the
operator control and display functions required by the distributor
and the system integrator (in the medical environment) for
operating the robot during start-up, maintenance and diagnosis.
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.
SSD Solid State Drive
Hard drive
KUKA Sunrise.OS KUKA Sunrise.Operating System
System Software for robots which are operated with the robot con-
troller KUKA Sunrise Cabinet
USB Universal Serial Bus
Bus system for connecting additional devices to a computer
Tool Applied part or medical instrument mounted on the robot via the
media flange.
EA External axis (linear unit, Posiflex)
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Introduction

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2 Product description
2.1 Overview of the robot system
The robot system (>>> Fig. 2-1) includes all assemblies, such as the ro-
bot (robot arm and the associated electrical installations), robot controller
and connecting cables.
The robot system consists of the following components:
• Robot (with media flange Inside electrical Med)
• KUKA Sunrise Cabinet Med robot controller
• KUKA smartPAD teach pendant (optional)
• Connecting cables
• KUKA Sunrise.OS Med software
• Options, accessories
Detailed information about the components of the robot system can be
found in the supplied documentation.
(>>> 13 "Appendix" Page 107)
Fig. 2-1: Overview of robot system (LBR Med)
1 Connecting cable to KUKA smartPAD
2 KUKA smartPAD teach pendant
3 Robot
4 Connecting cable to KUKA Sunrise Cabinet Med robot controller
5 KUKA Sunrise Cabinet Med robot controller
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Product description

2.2 KUKA Sunrise Cabinet Med
Overview
The KUKA Sunrise Cabinet Med robot controller consists of the following
components:
• Control PC
• smartPAD control panel
• Connection panel
The robot controller can be installed in a 19" rack.
Fig. 2-2: Overview of the robot controller
1 Low-voltage power supply unit
2 Memory card (EDS)
3 Power Management Board, Small Robot (PMB_SR)
4 Cabinet Interface Board, Small Robot (CIB_SR)
5 Interfaces
6 Device switch, interfaces, fuses
7 Network insulator
8 Network connections cover
9 DC/DC converter
10 Motherboard D3445-K interfaces
11 Fan
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2.3 Control PC
Components
The control PC includes the following components:
• Motherboard
• Processor
• Heat sink
• Memory modules
• Hard drive
• LAN Dual NIC network card (not present on all motherboard variants)
2.4 Cabinet Control Unit, Small Robot
Description
The Cabinet Control Unit, Small Robot (CCU_SR) is the central power dis-
tributor and communication interface for all components of the robot con-
troller. The CCU_SR consists of the Cabinet Interface Board, Small Robot
(CIB_SR) and the Power Management Board, Small Robot (PMB_SR). All
data are transferred via this internal communication interface to the con-
troller for further processing. If the mains voltage fails, the control compo-
nents continue to be powered by batteries until the position data are
saved and the controller has shut down. The charge and quality of the
batteries are checked by means of a load test.
The CCU_SR also incorporates sensing, control and switching functions.
The output signals are provided as electrically isolated outputs.
Functions
• Communication interface for the components of the robot controller
• Safe inputs and outputs
‒ Contactor activation
‒ 3 floating outputs
‒ 7 safe inputs
‒ Teach pendant connected
• Power supply fan monitoring
• Control box internal temperature
• The following components are connected to the KPC via the KUKA
Controller Bus:
‒ Power Drive System
• The following operator panels and service devices are connected to
the control PC via the KUKA System Bus:
‒ KUKA Operator Panel Interface
• Diagnostic LEDs
• Electronic Data Storage interface
Power supply with battery backup
• KUKA smartPAD
• Control PC quad-core processor
• Power Drive System
Power supply without battery backup
• Motor brakes
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• Customer interface
2.5 Low-voltage power supply
Description
The low-voltage power supply unit provides power to the components of
the robot controller and supplies the robot drives with 48 V DC.
Two green and two red LEDs indicate the operating state of the low-volt-
age power supply unit.
2.6 Batteries
In the event of a power failure, or if the power is switched off, the batter-
ies enable the robot controller to be shut down in a controlled manner.
The batteries are charged via the CCU_SR and the charge is checked
and indicated.
2.7 Description of interfaces
Overview
The connection panel of the KUKA Sunrise Cabinet Med robot controller
consists as standard of connections for the following cables:
• Device connection cable
• Robot cable
• smartPAD cable
• Peripheral cables
The configuration of the connection panel varies according to the custom-
er-specific version and the options required.
Connection panel
Fig. 2-3: KUKA Sunrise Cabinet Med interfaces
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Item Interface Item Interface
1 X11 interface 7 2 PE connections
2 X19 smartPAD interface 8 F2
3 X65 Extension interface 9 X1 Power supply connec-
tion
4 X69 Service interface 10 F1
5 X21 Robot interface (Med
variant)
11 Control PC interfaces
6 X66 KUKA Line Interface
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.
NOTICE
Only devices that meet the minimum requirements for separation from
the mains voltage according to IEC 60601-1 may be connected to the
robot controller:
• 2 x MOOP
• 1 x MOPP
(based on the maximum mains voltage of 230 V AC)
This minimum requirement corresponds to a separation of at least
3.4 mm clearance, 5.0 mm creepage distance and 3000 V dielectric
strength.
When connecting devices to the interfaces of the robot controller, the
medical product manufacturer must verify compliance with the permissible
limit values for leakage currents according to IEC 60601-1. In addition to
this, the requirements of IEC 60601-1 for ME systems must be taken into
consideration.
NOTICE
In its risk management process, the medical product manufacturer must
evaluate the overall system, including all devices connected to the inter-
faces.
2.7.1 Motherboard D3445-K PC interfaces
Overview
Fig. 2-4: Motherboard D3445-K interfaces
1 4 USB 2.0 ports
2 Display port
3 DVI-D
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4 2 USB 3.0 ports
5 LAN Onboard – KUKA Option Network Interface
KUKA Deutschland GmbH has assembled, tested and supplied the
motherboard with an optimum configuration. No liability will be accepted
for modifications to the configuration that have not been carried out by
KUKA Deutschland GmbH.
The USB interfaces can be used for integrating the controller into the
medical product. The medical product manufacturer must ensure that
the functionality of the medical product cannot be adversely affected,
e.g. by a test for malware or by restriction of the USB devices that may
be connected.
2.8 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!
Cooling circuit, control box
Fig. 2-5: Cooling circuit, control box
1 Air inlet 3 Air outlet
2 Fan
2.9 Intended use
Use
The KUKA Sunrise Cabinet Med robot controller is intended solely for op-
erating the LBR Med. The KUKA Sunrise Cabinet Med robot controller is
integrated into a medical device by a medical device manufacturer.
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Misuse
Any use or application deviating from the intended use is deemed to be
misuse and is not allowed. KUKA Deutschland GmbH is not liable for any
damage resulting from such misuse. The risk lies entirely with the medical
device manufacturer/user.
Examples of such misuse include:
• Use other than in medical applications (e.g. industry)
• Operation outside the specified operating parameters
• Operation in potentially explosive environments
• Outdoor operation
• Direct use in sterile environments
Operating life
The operating life of the robot system is 10,000 hours of operation.
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