Krc2 Perifery en

CONTROL CABINET
KR C2
Operating Handbook
Connection / Periphery
Issued: 01 Dec 2004

AnPerBed--HBKRC2 07.00.06 en
Version: 06
1 of 20
e Copyright
2004
KUKA Roboter GmbH

Zugspitzstrae 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
Contents
1
Connection panel overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector pin allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Power supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Service socket X01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Peripheral connector X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
KCP connector X19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
3 of 20
Operating Handbook
4 of 20
Connection panel overview
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
10
Control Panel
Connection panel, robot

X30/X30.2
X31
PE1
PE2
Data cable
Motor cable
Power cable
11
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).
5 of 20
Operating Handbook
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
1
Q1/1
Q1/2
Q1/3
X3/1 / N*
5
6
GND
PE
L1
L2
L3
N*
Not assigned
Not assigned
PE
XS1
Toroidal cores
Q1/1
Q1/2
Q1/3
Power connector
from the cabinet
Power infeed:
3 x 400 V 50/60 Hz xx A
Incoming supply only with
transformer:
3 x 380 V 50/60 Hz xx A
3 x 440 V 50/60 Hz xx A
3 x 480 V 50/60 Hz xx A
3 x 575 V 50/60 Hz xx A
min. 3x25 A
max. 3x32 A
* For all connections, N--conductor

is only necessary for the service
socket option with a 400 V power
supply.
GND
Service socket X01

X01
F4/2
X3/1
L
N
PE
6 of 20
XS1:
Fusing
X3/1 / N*
2.2
Connection examples:
X1:
Harting socket
installed in the
connector panel
Optional service
socket
(Standard version for
neutral conductor in the
power supply!)
Supply voltage depends on
the power supply used;
max. capacity 6 A
2.3
Connector pin allocation (continued)
Peripheral connector X11

X11
Safety module ESC board
X9
1
38
5
6
19
23
25
39
10
22
Test output A
Test output A
Test output A
Test output B
Test output B
Test output B
Test output B
External E--STOP channel A

External E--STOP channel B
X10
1
Enabling channel A
24
Enabling channel B
26
12
41
Test output A
11
42
Drives OFF external
10
43
44
Drives ON external
50
Qualifying input A
51
Qualifying input B
X12
Test output A
Safeguard channel A
Safeguard channel B
Test output B
Optional
1
90
DC 27 V control voltage 6 A
36
DC 27 V control voltage 4 A
72
18
0 V control voltage
0 V control voltage
7 of 20
Operating Handbook
Peripheral interface X11 (continued)
X11
Safety module ESC board
X11
1
46
47
48
10
20
11
21
30
29
12
Drives ON channel A
10
11
Drives ON channel A
88
89
106
107
X12
AUTO mode
TEST mode
COM mode
Local E--STOP channel B
Local E--STOP channel A
Drives ON channel B
Drives ON channel B
X6
+24 V for safety circuit
GND safety circuit
+24 V internal max. 4 A

0 V internal
More detailed information on the X11 interface can be found under 2.8.
8 of 20
2.4
KCP connector X19
X19
KVGA
1
wh
bn
DISPLAY--
gn
ye
Spare
DISPLAY+
Spare
SHIELD
SHIELD
A1.2
X5
24 V internal
0 V int.
+VCC
GND
ESC IN (B)
ESC IN (A)
ESC OUT (B)
ESC OUT (A)
rd
bu
pk
gy
wh
bn
gn
6
7
ye
8
9
10
CAN +
CAN --
gn
10
bk
NC
NC
12
11
+24 V KCP voltage

GND
+24 V ESC voltage
GND
ESC In (B)
ESC In (A)
ESC Out (B)
ESC Out (A)
CAN +
CAN --
9 of 20
Operating Handbook
2.5
Motor connector X20, axes 1 to 6
X20
N1
N2
N3
N4
N5
N6
4 X2
a1
a2
a3
4 X2
b1
b2
b3
4 X2
c1
c2
c3
4 X2
d1
d4
d6
4 X2
e1
e4
e6
4 X2
f1
f4
f6
Motor A1--V1
Motor A1--W1
Motor A2--U1
Motor A2--V1
Motor A2--W1
Motor A3--U1
Motor A3--V1
Motor A3--W1
Motor A4--U1
Motor A4--V1
Motor A4--W1
Motor A5--U1
Motor A5--V1
Motor A5--W1
Motor A6--U1
Motor A6--V1
Motor A6--W1
d3
F19.2
e3
F19.4
f3
F19.6
B--
X2
Motor A1 -- A6 brake +
d5
e5
f5
PE
10 of 20
Motor A1--U1
Motor A1 -- A6 brake --
Ground conductor 6.0 mm2
2.6
Optional motor connector X7
X7
X3
N1
b1
b2
b3
X3
N2
c1
c2
c3
X3
N3
d1
d2
d3
F14.2
G1
X114 --7
Motor A1--V2
Motor A1--W2
Motor A2--U2
Motor A2--V2
Motor A2--W2
Motor A3--U2
Motor A3--V2
Motor A3--W2
a1
a2
PE
Motor A1--U2
Connector monitoring
Ground
11 of 20
Operating Handbook
2.7
Data cable connector X21, axes 1 to 8
X21
1
2
X2: 12
F16
NC
GND
+27 V DC
RDC
Connector 4
A32
11
BK
BN
BK
12
RD
BK
13
OG
BK
10
YE
11
10
BK
12
GN
13
14
BK
14
BU
15
16
17
/CLKX
CLKX
FSR
/FSR
DR
/DR
/FSX
FSX
/DX
DX
/CLKR
CLKR
NC
NC
Housing
12 of 20
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
ESC power supply

max. 2 A
24 V control voltage
+24 V internal
0 V internal
106
107
+VCC external
0 V external
88
89
In the absence of an external

power supply, 24 V / 0 V must be
jumpered internally
An external power supply is

recommended for interlinked
systems.
+27 V
0V
36
18
for supply to external devices
max. 4 A
Optional. This control voltage is

available to the customer.
Caution: max. 4 A
+27 V
0V
90
72
for supply to external devices
max. 6 A
Optional. This control voltage is

available to the customer.
Caution: max. 6 A
Test output A
(test signal)
1
5
7
38
41
Makes the clocked voltage

available for the individual
interface inputs of channel A.
Connection example:
enabling switch is connected
under channel A to pin 1 (TA_A)
and pin 6 (A).
Test output B
(test signal)
19
23
25
39
43
Makes the clocked voltage

available for the individual
interface inputs of channel B.
Connection example:
safety gate locking mechanism is
connected under channel B to pin
19 (TA_B) and pin 26 (B).
In the non--activated state, the
contacts are closed
Local E--STOP
Channel A
Channel B
20 /21
2/3
Output, floating contacts from

internal E--STOP
max. 24 V, 600 mA
External E--STOP
Channel A
Channel B
4
22
Dual--channel E--STOP input.

max. 24 V, 10 mA
max. 24 V, 10 mA
Enabling switch
Channel A
Channel B
6
24
Safeguard
Channel A
Channel B
8
26
For connection of an external

dual--channel enabling switch with
floating contacts
max. 24 V, 10 mA
If no enabling switch is connected,

pins 5 and 6 and pins 23 and 24
must be jumpered.
Only effective in TEST mode
For 2--channel connection of a

safety gate locking mechanism
max. 24 V, 10 mA
Only effective in AUTOMATIC

mode
13 of 20
Operating Handbook
Interface signal
Pin
Description
Remarks
Drives OFF external
42
A floating contact (break contact)

can be connected to this input. If
the contact opens, the drives are
switched off.
max. 24 V, 10 mA
If this input is not used, pins 41/42

must be jumpered.
44
For connection of a floating

contact.
Pulse > 200 ms switches drives on.

Signal must not be permanently
active.
Floating contacts signal

Drives ON.
Is closed if the Drives ON

contactor is energized.
Channel A
(single--channel)
Drives ON external
Channel B
(single--channel)
Drives ON
Channel A
Channel B
11 / 12
29 / 30
(These contacts are only available if an ESC--CI board is

used)
Operating mode
groups
Automatic
Test
Qualifying input
Channel A
Channel B
Floating contacts of the safety

48 / 46 relay signal the operating mode.
48 / 47
(These contacts are only available if an ESC--CI board is
used)
50
51
Test contact 48/47 is closed if

Test1 or Test2 is selected on the
KCP.
Automatic contact 48/46 is closed
if Automatic or External is selected
on the KCP.
Input reserved for future functions. If these inputs are not used, pin 50
(0 signal causes a category 0
must be jumpered to test output
STOP in all operating modes)
38, and pin 51 to test output 39.
When establishing connections, observe the technical data in your specifications!
14 of 20
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
107
0 V internal
89
106
24 V internal
88
ESC
20
21
Test output A
Test output B
19
22
PLC
External
E--STOP
in the
periphery
Emergency Stop circuit for one robot with periphery
15 of 20
Operating Handbook
X11
107
0 V internal
89
24 V internal
106
88
ESC
0V
external
20
21
Test output A
Test output B
19
22
24 V
external
PLC
External
E--STOP
in the
periphery
Emergency Stop circuit for one robot with periphery

and external power supply
16 of 20
X11
Control voltage, external
0V
107
0V
72
24 V
16
Control voltage
90
L+
36
Y3
S11
Safeguard
S22
S12
External
enabling switch
System
E--STOP
24
14
Drives
Emergency Stop switching device (e.g. PNOZ 10)
S21
43
X11 --
89 88
20 2
26
Safeguard channel B
Safeguard channel A
24
Enabling channel B
Enabling channel A
22
42
Drives OFF external
39
24 V test output B
25
24 V test output B
23
24 V test output B
19
24 V test output B
38
24 V test output A
24 V test output A
24 V test output A
24 V test output A
Power supply for safety circuit

19
OFF
34
20
Drives ON external
33
ON
13
22
21
44
23
44
24 V
106
L--
88
24 V external VCC
89
0 V external GND
ESC
board
21 3
robot 2
Connection example of E--STOP circuits with 2 robots connected via

peripheral connector X11
17 of 20
Operating Handbook
2.10
Safety gate monitor

L+
Safety gate monitor
A1 (+)
e.g. PST3, manuf.: Pilz
Ue
L --= safety gate open
A2 ( ---)
S11
= safety gate closed

= actuated element
S12
Gate position switches
S23
S24
X1
X2
23
24
25
26
Safeguard channel B
14
Test output A
Peripheral connector X11
13
Test output B
This pushbutton must be

located outside the space
limited by the safeguards.
Safeguard channel A
Pushbutton for enable

with safety gate closed
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.
18 of 20
2.11
Service jumper plug for X11 -- KR C2

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

Test output A
Enabling channel A
Test output A
Safeguard channel A
Test output B
Safeguard channel B
Test output B
Test output B
Enabling channel B
Test output A
Test output B
Test output channel A

External Drives OFF
Qualifying input A
Qualifying input B
+VCC external
GND external
+24 V internal
0 V internal
1
2
3
4
5
6
7
8
25
26
Safeguard
Test output A
19
20
21
22
23
24
38
39
41
42
50
51
88
89
106
107
19 of 20
Operating Handbook
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

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CONTROL CABINET

Issued: 01 Dec 2004

KUKA Roboter GmbH

Connection panel overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector pin allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service socket X01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Peripheral connector X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KCP connector X19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor connector X20, axes 1 to 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional motor connector X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data cable connector X21, axes 1 to 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interface signals X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMERGENCY STOP circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety gate monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service jumper plug for X11 -- KR C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection panel overview

Connection panel overview

Connection panel, robot

Fig. 1 Cable connections

Power supply connection X1

Motor connector X20

Motor connector X7*

KCP connection X19

Data cable X21

[PE1] Main infeed ground conductor

[PE2] Equipotential bonding for

Customer interface X11

X7 = optional cross--sectional reinforcement for robots with high payloads

Connector pin allocation

Power supply connection

* For all connections, N--conductor

Service socket X01

Connector pin allocation (continued)

Peripheral connector X11

Safety module ESC board

External E--STOP channel A

Drives OFF external

Peripheral interface X11 (continued)

Safety module ESC board

+24 V internal max. 4 A

Connector pin allocation (continued)

KCP connector X19

+24 V KCP voltage

Motor connector X20, axes 1 to 6

Ground conductor 6.0 mm2

Connector pin allocation (continued)

Optional motor connector X7

Data cable connector X21, axes 1 to 8

Connector pin allocation (continued)

Interface signals X11

ESC power supply

In the absence of an external

An external power supply is

Optional. This control voltage is

Optional. This control voltage is

Makes the clocked voltage

Makes the clocked voltage

Output, floating contacts from

Dual--channel E--STOP input.

For connection of an external

If no enabling switch is connected,

For 2--channel connection of a