ROBOT

(V)KR 180 PA; (V)KR 100, 180--2 PA

Description

Energy Supply System, Handling, A 1 -- A 5

Valid for Art. no. 00--126--226

Issued: 22 Feb 2005 Version: 00

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e Copyright KUKA Roboter GmbH
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.

PD Interleaf

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Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Description

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 1 General

Valid for (V)KR 180 PA; (V)KR 100, 180--2 PA

1 General
For use in certain production technologies, the robot can be equipped with an energy supply
system for handling (Fig. 1) installed in the area between the base frame and the swing
frame. The energy supply system consists of a dress package for A 1 -- A 5 for transmitting
the energy, fluids and signals typical of the technological process concerned, and the
“holders for energy supply system” required for attaching it to the robot.
The energy supply system A 1 -- A 5 accommodates the electric cables and ensures that
they are guided with minimum stress throughout the permitted working envelope. It is
installed between interface A 1 (Fig. 1/14) on the base frame (13) and interface A 5 (5) on
the swing frame (6), and consists of an application--specific dress package (9) with flexible
tubes (3, 11, 15) and the associated cables and hoses. Flexible tube (15) is installed in the
base frame (13) behind a protective cover (16), while flexible tube (11) is fastened to the
rotating column (10) and to the link arm (8), under the cover (7), by means of holders (17)
and hinged clamps (12). Flexible tube (3) is fastened to the arm (18) and swing frame (6) by
means of holders (1, 4) and hinged clamps (2).
The energy supply system is attached to the robot in such a way that the dress package does
not hinder the motion of the robot, while ensuring that the dress package has maximum
freedom of movement with minimum wear.
The cables and hoses are connected to an interface on the base frame (interface A 1) and
on the swing frame (interface A 5).
The design of the energy supply system is suitable for most applications in terms of reach
and resistance to wear. There may, of course, be program--specific applications for which
this version is of only limited use. A special version is required in such cases, or alternatively
a corresponding adaptation of the energy supply system or modification of the program
sequence.

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Description

1 2 3 2

18

17 6
7

17

10
16
11
15
14 12

13

1 Holder, arm 10 Rotating column

2 Hinged clamp, arm 11 Flexible tube
3 Flexible tube 12 Hinged clamp, base frame
4 Holder, swing frame 13 Base frame
5 Interface A 5, swing frame 14 Interface A 1, base frame
6 Swing frame 15 Flexible tube
7 Cover, link arm 16 Cover, base frame
8 Link arm 17 Holder, link arm
9 Dress package 18 Arm

Fig. 1 Energy supply system, handling, A 1 -- A 5

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 1 General (continued)

1 2
Base frame

XM7.1
X76

1 Control cable
2 Motor cable for single axis
3 Control cable without connectors
4 Control cable for single axis
4 3

Swing frame
1 2

1 Motor cable for single axis

2 Control cable for single axis
3 Control cable

Fig. 2 Interface on base frame and swing frame for motor and control cables

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Description

2 Technical data
D KUKA article numbers
-- Energy supply system assy Art. no. 00--126--226
-- Dress package Art. no. 00--126--181

D Wiring diagrams
-- Fig. 3 to Fig. 6

D Control cable, X76 -- X106

-- Rated voltage 250 V AC
-- Current max. 5A
-- Connection 25--pole HAN 25 D surface--mounted housing
with crimp terminals on base frame and wrist.
The exact connector designation may be
noted from the parts list.

D Control cable without connectors

-- Configuration 23x 1 mm2 + (2x 1 mm2), shielded
-- Rated voltage 250 V AC
-- Current max. 5A

D Control cable for single axis, X7 -- XP7.5

-- Configuration 4x (2x 0.25 mm2)
shielded in pairs
-- Rated voltage 250 V AC
-- Current max. 1 A for 0.25 mm2
-- Connection Connectors at both ends
Lumberg male connector on base frame
Intercontec female connector on wrist
The exact connector designation may be
noted from the parts list.

D Motor cable for single axis, XM7.1 -- XM7.5

-- Configuration 4x 2.5 mm2
2x 0.5 mm2, overall shield
-- Rated voltage 450 V/750 V (Uo/U) for 2.5 mm2
300 V for 0.5 mm2
-- Current max. 16 A for 2.5 mm2
2 A for 0.5 mm2
-- Connection Intercontec male coupling on base frame
Intercontec female connector on wrist
The exact connector designation may be
noted from the parts list.

In the case of multi--strand cables, the derating factors specified in EN 60204

must be taken into account.

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 2 Technical data (continued)

D Air line
-- Hose 1/2”, blue
-- Connection at interface A 1 with bulkhead union, straight, M22x1.5
-- Connection at interface A 5 with bulkhead union, straight, M22x1.5
-- Pressure max. 2.0 MPa

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Description

3 Wiring diagrams

Wiring diagram

Connector Pin Wire Strip Wire Connector Pin Signal designation

X YE/GN X Grd. conductor
Control signal

Fig. 3 Wiring diagram, control cable without connectors,

23x 1 mm2 and (2x1 mm2), shielded

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 3 Wiring diagrams (continued)

Wiring diagram
Connector Pin Wire Strip Wire Connector Pin Signal designation
X76 YE/GN X106 Grd. conductor
Control signal

Guide pin
09 33 000 9908
Guide bush
09 33 000 9909

X76 X106

Fig. 4 Wiring diagram for control cable

WIRING DIAGRAM
Connector Pin Wire Strip Wire Connector Pin Signal designation
X7 XP7.5
0.25 mm2 BN
0.25 mm2 WH
Shield
0.25 mm2 YE
0.25 mm2 GN

0.25 mm2 PK
0.25 mm2 GY
0.25 mm2 RD
0.25 mm2 BU
Housing Shield
Shield
Shield

Fig. 5 Wiring diagram, control cable for single axis

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Description

WIRING DIAGRAM
Connector Pin Wire Wire Wire Connector Pin Signal designation
XM7.1 XM7.5

RD Brake +
BU Brake --
GN/YE Ground conductor
Housing Shield, connector housing

Fig. 6 Wiring diagram, motor cable for single axis

1

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