CONTROL CABINET

KR C2

Operating Handbook

Connection / Periphery

Issued: 01 Dec 2004 Version: 06

AnPerBed--HBKRC2 07.00.06 en
1 of 20
e Copyright 2004

KUKA Roboter GmbH

Zugspitzstraße 140
D--86165 Augsburg

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim 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, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

2 of 20
AnPerBed--HBKRC2 07.00.06 en
Contents

1 Connection panel overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Connector pin allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Power supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Service socket X01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Peripheral connector X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 KCP connector X19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Motor connector X20, axes 1 to 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Optional motor connector X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7 Data cable connector X21, axes 1 to 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Interface signals X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.9 EMERGENCY STOP circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10 Safety gate monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.11 Service jumper plug for X11 -- KR C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

AnPerBed--HBKRC2 07.00.06 en
3 of 20
 Operating Handbook

AnPerBed--HBKRC2 07.00.06 en
4 of 20
 1 Connection panel overview

1 Connection panel overview

All the connectors on the connector panel are plug--and--socket connections as defined by
VDE 0627.
Accordingly, these plug--and--socket connections must not be plugged or unplugged while
the controller is operational (i.e. energized).
Before these plug--and--socket connections are plugged or unplugged, the controller and
the cables concerned must be deenergized.

KUKA Control Panel

Connection panel
KR C2 control cabinet

1 2 3 4 5 6 7 8 9
10
11

Control Panel
Connection panel, robot
Power cable

Motor cable

Data cable

X30/X30.2 X31
PE1
PE2

Fig. 1 Cable connections

Legend
[1] Power supply connection X1 [8] Option
[2] Motor connector X20 [9] Option
[3] Motor connector X7* [10] KCP connection X19
[4] Option [11] Data cable X21
[5] Option [PE1] Main infeed ground conductor
[6] Option [PE2] Equipotential bonding for
external system components
[7] Customer interface X11
* X7 = optional cross--sectional reinforcement for robots with high payloads

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

AnPerBed--HBKRC2 07.00.06 en
5 of 20
 Operating Handbook

2 Connector pin allocation

Detailed information on connector pin allocation may be found in the corresponding “Circuit
diagrams” and “Cabling description”.

2.1 Power supply connection

Caution: connecting cable with toroidal
cores

Toroidal cores X1 Connection examples:

X1: Harting socket
1 L1 installed in the
Q1/1 connector panel
2
Q1/2 L2
3 XS1: Power connector
Q1/3 L3
from the cabinet
4
X3/1 / N* N*
5 Not assigned
6 Not assigned
Power infeed:
GND 3 x 400 V 50/60 Hz xx A
PE PE
Incoming supply only with
transformer:
3 x 380 V 50/60 Hz xx A
3 x 440 V 50/60 Hz xx A
Toroidal cores XS1 3 x 480 V 50/60 Hz xx A
3 x 575 V 50/60 Hz xx A
Q1/1
Q1/2 Fusing min. 3x25 A
Q1/3 max. 3x32 A
* For all connections, N--conductor
X3/1 / N* is only necessary for the service
GND socket option with a 400 V power
supply.

2.2 Service socket X01

X01 Optional service
socket
L (Standard version for
F4/2
neutral conductor in the
N power supply!)
X3/1

PE Supply voltage depends on

the power supply used;
max. capacity 6 A

AnPerBed--HBKRC2 07.00.06 en
6 of 20
 2 Connector pin allocation (continued)

2.3 Peripheral connector X11

X11
X9
1 1
Test output A
2 5
Test output A
3 7
Test output A
4 38
Test output A

5 19
Test output B
6 23
Test output B
7 25
Test output B
8 39
Test output B

9 4
External E--STOP channel A
10 22
Safety module ESC board

External E--STOP channel B

X10
1 6 Enabling channel A
2 24 Enabling channel B

3 8 Safeguard channel A
4 26
Safeguard channel B

12 41 Test output A
11 42 Drives OFF external
10 43
Test output B
9 44 Drives ON external

5 50 Qualifying input A
6 51 Qualifying input B

X12 Optional
1 90 DC 27 V control voltage 6 A
2 36 DC 27 V control voltage 4 A
3 72
0 V control voltage
4 18 0 V control voltage

AnPerBed--HBKRC2 07.00.06 en
7 of 20
 Operating Handbook

Peripheral interface X11 (continued)

X11
X11
1 46
AUTO mode
2 47 TEST mode
3 48
COM mode

8 2 Local E--STOP channel B

9 3
Local E--STOP channel B
10 20
Local E--STOP channel A
11 21
Local E--STOP channel A
Safety module ESC board

X12
6 30
Drives ON channel B
7 29
Drives ON channel B

9 12 Drives ON channel A
10 11 Drives ON channel A

X6
3 88
+24 V for safety circuit
4 89
GND safety circuit

7 106
+24 V internal max. 4 A
8 107
0 V internal

More detailed information on the X11 interface can be found under 2.8.

AnPerBed--HBKRC2 07.00.06 en
8 of 20
 2 Connector pin allocation (continued)

2.4 KCP connector X19

KVGA X19

1 wh A
DISPLAY+
2 bn B DISPLAY--
3 gn C Spare
4 ye D
Spare

SHIELD

SHIELD

A1.2

X5
1 rd 1
24 V internal +24 V KCP voltage
2 bu 2
0 V int. GND
3 pk 3
+VCC +24 V ESC voltage
4 gy 4
GND GND
5 wh 5
ESC IN (B) ESC In (B)
ESC IN (A) 6 bn 6 ESC In (A)
7 gn 7
ESC OUT (B) ESC Out (B)
8 ye 8
ESC OUT (A) ESC Out (A)
9 gn 9
CAN + CAN +
10 bk 10
CAN -- CAN --
11
NC
12
NC

AnPerBed--HBKRC2 07.00.06 en
9 of 20
 Operating Handbook

2.5 Motor connector X20, axes 1 to 6

X20
4 X2 a1
Motor A1--U1
N1 3 a2
Motor A1--V1
2 a3
Motor A1--W1

4 X2 b1
Motor A2--U1
N2 3 b2
Motor A2--V1
2 b3
Motor A2--W1

4 X2 c1
Motor A3--U1
N3 3 c2
Motor A3--V1
2 c3
Motor A3--W1

4 X2 d1
Motor A4--U1
N4 3 d4
Motor A4--V1
2 d6
Motor A4--W1

4 X2 e1
Motor A5--U1
N5 3 e4
Motor A5--V1
2 e6
Motor A5--W1

4 X2 f1
Motor A6--U1
N6 3 f4
Motor A6--V1
2 f6
Motor A6--W1

F19.2
d3
e3
F19.4 Motor A1 -- A6 brake +
F19.6
f3
X2
B-- d5
e5
Motor A1 -- A6 brake --
f5

PE
Ground conductor 6.0 mm2

AnPerBed--HBKRC2 07.00.06 en
10 of 20
 2 Connector pin allocation (continued)

2.6 Optional motor connector X7

X7
X3
4 b1
Motor A1--U2
N1 3 b2
Motor A1--V2
2 b3
Motor A1--W2

X3
4 c1
Motor A2--U2
N2 3 c2
Motor A2--V2
2 c3
Motor A2--W2

X3
4 d1
Motor A3--U2
N3 3 d2
Motor A3--V2
2 d3
Motor A3--W2

F14.2
a1

Connector monitoring
G1 X114 --7
a2

PE
Ground

AnPerBed--HBKRC2 07.00.06 en
11 of 20
 Operating Handbook

2.7 Data cable connector X21, axes 1 to 8

X21

1
NC
2
X2: 12 GND
3 RDC
F16 +27 V DC

A32
11 BK 4
/CLKX
3 BN 5
CLKX
4 BK 6
FSR
12 RD 7
/FSR
5 BK 8
Connector 4

DR
13 OG 9
/DR
9 BK 10
/FSX
1 YE 11
FSX
10 BK 12
/DX
2 GN 13
DX
14 BK 14
/CLKR
6 BU 15
CLKR

16
NC
17
NC

Housing

AnPerBed--HBKRC2 07.00.06 en
12 of 20
 2 Connector pin allocation (continued)

2.8 Interface signals X11

Jumpering or cross--connection of dual--channel inputs is not permitted and

causes immediate disconnection of the drives!

Interface signal Pin Description Remarks

24 V control voltage ESC power supply
+24 V internal 106 max. 2 A
0 V internal 107
24 V control voltage In the absence of an external An external power supply is
+VCC external 88 power supply, 24 V / 0 V must be recommended for interlinked
0 V external 89 jumpered internally systems.
27 V control voltage 27 V control voltage Optional. This control voltage is
+27 V 36 for supply to external devices available to the customer.
0V 18 max. 4 A Caution: max. 4 A
27 V control voltage 27 V control voltage Optional. This control voltage is
+27 V 90 for supply to external devices available to the customer.
0V 72 max. 6 A Caution: max. 6 A
Test output A 1 Makes the clocked voltage Connection example:
(test signal) 5 available for the individual enabling switch is connected
7 interface inputs of channel A. under channel A to pin 1 (TA_A)
38 and pin 6 (A).
41
Test output B 19 Makes the clocked voltage Connection example:
(test signal) 23 available for the individual safety gate locking mechanism is
25 interface inputs of channel B. connected under channel B to pin
39 19 (TA_B) and pin 26 (B).
43
Local E--STOP Output, floating contacts from In the non--activated state, the
Channel A 20 /21 internal E--STOP contacts are closed
Channel B 2/3 max. 24 V, 600 mA
External E--STOP Dual--channel E--STOP input.
Channel A 4 max. 24 V, 10 mA
Channel B 22 max. 24 V, 10 mA
Enabling switch For connection of an external If no enabling switch is connected,
Channel A 6 dual--channel enabling switch with pins 5 and 6 and pins 23 and 24
Channel B 24 floating contacts must be jumpered.
max. 24 V, 10 mA Only effective in TEST mode
Safeguard For 2--channel connection of a Only effective in AUTOMATIC
Channel A 8 safety gate locking mechanism mode
Channel B 26 max. 24 V, 10 mA

AnPerBed--HBKRC2 07.00.06 en
13 of 20
 Operating Handbook

Interface signal Pin Description Remarks

Drives OFF external 42 A floating contact (break contact) If this input is not used, pins 41/42
can be connected to this input. If must be jumpered.
Channel A the contact opens, the drives are
(single--channel) switched off.
max. 24 V, 10 mA
Drives ON external 44 For connection of a floating Pulse > 200 ms switches drives on.
contact. Signal must not be permanently
Channel B active.
(single--channel)
Drives ON Floating contacts signal Is closed if the “Drives ON”
Channel A 11 / 12 “Drives ON”. contactor is energized.
Channel B 29 / 30
(These contacts are only avail-
able if an ESC--CI board is
used)
Operating mode Floating contacts of the safety Test contact 48/47 is closed if
groups 48 / 46 relay signal the operating mode. Test1 or Test2 is selected on the
Automatic 48 / 47 KCP.
Test (These contacts are only avail- Automatic contact 48/46 is closed
able if an ESC--CI board is if Automatic or External is selected
used) on the KCP.
Qualifying input Input reserved for future functions. If these inputs are not used, pin 50
Channel A 50 (0 signal causes a category 0 must be jumpered to test output
Channel B 51 STOP in all operating modes) 38, and pin 51 to test output 39.

When establishing connections, observe the technical data in your specifications!

AnPerBed--HBKRC2 07.00.06 en
14 of 20
 2 Connector pin allocation (continued)

2.9 EMERGENCY STOP circuits

Emergency Stop circuit, safeguard, and ext. enabling switch are signals that serve
safety purposes and must be used in accordance with DIN EN 60204--1 and EN 775.

The following examples show how the robot EMERGENCY STOP circuit can be connected
to other robots or to the periphery.

X11
0 V internal 107

89

24 V internal 106

88

Local E--STOP channel B 2

Local E--STOP channel B 3

PLC
Local E--STOP channel A 20

Local E--STOP channel A 21

Test output A 1

External E--STOP channel A 4

ESC
Test output B 19

External E--STOP channel B 22

External
E--STOP
in the
periphery
Emergency Stop circuit for one robot with periphery

AnPerBed--HBKRC2 07.00.06 en
15 of 20
 Operating Handbook

X11
0 V internal 107

89 0V
external
24 V internal 106

88 24 V
external

Local E--STOP channel B 2

Local E--STOP channel B 3

PLC
Local E--STOP channel A 20

Local E--STOP channel A 21

Test output A 1

External E--STOP channel A 4

ESC
Test output B 19

External E--STOP channel B 22

External
E--STOP
in the
periphery

Emergency Stop circuit for one robot with periphery

and external power supply

AnPerBed--HBKRC2 07.00.06 en
16 of 20
 2 Connector pin allocation (continued)

Control voltage, external

X11
107 0V

72
0V 24 V
16
Control voltage
106 24 V
L-- 90
L+
36

21 Local E--STOP channel A

S21
20 Local E--STOP channel A
Y3
Emergency Stop switching device (e.g. PNOZ 10)

3 Local E--STOP channel B

S11
2 Local E--STOP channel B

Safeguard 26 Safeguard channel B

S22
8 Safeguard channel A
S12
System External 24 Enabling channel B

E--STOP enabling switch 6 Enabling channel A

24
22 External E--STOP channel B ESC
4 External E--STOP channel A board
14
ON 44 Drives ON external

OFF 42 Drives OFF external

Drives

43

33 39 24 V test output B

25 24 V test output B

23 24 V test output B

19 24 V test output B
23
38 24 V test output A

7 24 V test output A

5 24 V test output A

1 24 V test output A
13

44 34 88 24 V external VCC

Power supply for safety circuit 89 0 V external GND

22 4 1 19 89 88 20 2 21 3

X11 -- robot 2

Connection example of E--STOP circuits with 2 robots connected via

peripheral connector X11

AnPerBed--HBKRC2 07.00.06 en
17 of 20
 Operating Handbook

2.10 Safety gate monitor

L+ A1 (+) Safety gate monitor

Ue e.g. PST3, manuf.: Pilz

L --- A2 ( ---)

= safety gate open

S11
= safety gate closed

= actuated element
S12

Gate position switches S23

S24

X1

Pushbutton for enable

with safety gate closed X2
13 14 23 24
This pushbutton must be
located outside the space
limited by the safeguards.

7 8 25 26
Peripheral connector X11
Safeguard channel A

Safeguard channel B
Test output B
Test output A

KR C2

Light barriers, photoelectric curtains or zone scanners must be installed in addition to

or instead of safety fences. They must be connected to the overall EMERGENCY STOP
system.
Irrespective of these safeguarding measures, the danger zone is to be indicated by means
of paint markings on the floor. These markings must differ distinctly in form, color and style
from other markings within the machine or plant in which the robot system is integrated.

AnPerBed--HBKRC2 07.00.06 en
18 of 20
 2 Connector pin allocation (continued)

2.11 Service jumper plug for X11 -- KR C2

The jumper plugs is only to be used during commissioning and troubleshooting.

1
Test output A
2
Local E--STOP channel B
3
Local E--STOP channel B
4
External E--STOP channel A

5
Test output A
6
Enabling channel A
7
Test output A
8

Safeguard
Safeguard channel A
25
Test output B
26
Safeguard channel B
Test output B 19
20
Local E--STOP channel A
21
Local E--STOP channel A
22
External E--STOP channel B
23
Test output B
Enabling channel B 24

38
Test output A

Test output B 39

41
Test output channel A
42
External Drives OFF
Qualifying input A 50
51
Qualifying input B

88
+VCC external
89
GND external
106
+24 V internal
0 V internal 107

AnPerBed--HBKRC2 07.00.06 en
19 of 20
 Operating Handbook

AnPerBed--HBKRC2 07.00.06 en
20 of 20
 Index

C
Connection panel, 5
Connector pin allocation, 6

D
Data cable connector X21, 12

E
EMERGENCY STOP circuits, 15

I
Interface signals X11, 13

K
KCP connector X19, 9
KUKA Control Panel, 5

M
Motor connector X20, 10
Motor connector X7, 11

P
Peripheral connector X11, 7
Power supply connection X1/XS1, 6

S
Safety gate monitor, 18
Service jumper plug X11, 19
Service socket X01, 6

X
X11, 7, 8

Index -- i