MA KR C4 Interfaces en

Controller Option
Optional Interfaces
For KR C4 Robot Controllers
Assembly and Operating Instructions
Issued: 02.05.2019
MA KR C4 Interfaces V13
KUKA Deutschland GmbH
Optional Interfaces
© Copyright 2019
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 MA KR C4 Interfaces (PDF) en

PB2932
Book structure: MA KR C4 Interfaces V11.1

BS515
Version: MA KR C4 Interfaces V13
2/106 | www.kuka.com MA KR C4 Interfaces V13 | Issued: 02.05.2019

Optional Interfaces
Contents
1 Introduction.............................................................................................. 7
1.1 Industrial robot documentation.............................................................................. 7
1.2 Representation of warnings and notes................................................................. 7
1.3 Trademarks............................................................................................................ 8
1.4 Terms used............................................................................................................ 8
2 Purpose..................................................................................................... 11
2.1 Target group.......................................................................................................... 11
2.2 Intended use.......................................................................................................... 11
3 Product description................................................................................. 13
3.1 Overview of the KR C4 robot controller............................................................... 13
3.2 Optional interfaces, connection panel................................................................... 13
3.3 Lower connection panel........................................................................................ 14
3.4 E67 interface, upper side connection panel......................................................... 21
3.5 KLI/KSI interfaces.................................................................................................. 22
3.6 Digital I/O modules and bus coupler.................................................................... 22
3.6.1 Digital I/O modules 16/16..................................................................................... 22
3.6.2 Digital I/O modules 16/16/4.................................................................................. 23
3.6.3 Digital I/O interface 32/32/4.................................................................................. 24
3.6.4 EtherCAT modules and switching devices, E67 interface................................... 25
3.7 Low-voltage power supply unit............................................................................. 26
3.8 Safety Interface Board.......................................................................................... 27
3.9 24 V external power supply.................................................................................. 27
4 Technical data.......................................................................................... 29
4.1 Safety Interface Board Extended.......................................................................... 29
4.2 Low-voltage power supply unit 24 V/10 A........................................................... 30
4.3 External 24 V power supply.................................................................................. 30
5 Safety......................................................................................................... 31
6 Planning.................................................................................................... 33
6.1 Discrete interfaces for safety options................................................................... 34
6.1.1 X13 SafeOperation interface................................................................................. 34
6.1.1.1 X13 SafeOperation interface................................................................................. 35
6.1.1.2 X13 SafeRangeMonitoring interface..................................................................... 37
6.1.1.3 X13 SafeSingleBrake interface............................................................................. 39
6.1.1.4 Wiring examples for safe inputs and outputs....................................................... 41
6.1.2 X53 “Drives ready” lamp....................................................................................... 43
6.1.3 X42 reference switch............................................................................................. 43
6.1.4 X58 external enabling switches............................................................................ 43
6.2 External power supplies........................................................................................ 45
6.2.1 X11 external power supply.................................................................................... 45
6.2.2 X55 external power supply................................................................................... 46
6.3 Low-voltage power supply unit 24 V/10 A........................................................... 46
6.4 Load voltages........................................................................................................ 47
6.4.1 X11 load voltage US1/US2................................................................................... 47
MA KR C4 Interfaces V13 | Issued: 02.05.2019 www.kuka.com | 3/106

Optional Interfaces
6.4.2 X56 load voltages US1/US2................................................................................. 48

6.4.3 X54 interface 27V PWR US1............................................................................... 49
6.4.4 Checking the US2 function, load voltage contactor............................................. 49
6.4.5 X14B interface 27V PWR US1/US2..................................................................... 50
6.4.6 X14B interface 27V PWR US1............................................................................. 51
6.4.7 X14B interface 27V PWR NA US1/US2............................................................... 52
6.4.8 X14B interface 24V PWR NA US1/US2............................................................... 52
6.4.9 X14B2 and X14B interface 24 V PWR US1/US2................................................ 53
6.5 Infeed..................................................................................................................... 54
6.5.1 X14A interface 27V PWR IN NA.......................................................................... 54
6.5.2 X14A interface 27V PWR IN................................................................................ 55
6.5.3 X14A interface 24V PWR IN NA.......................................................................... 55
6.6 Ethernet interfaces................................................................................................ 56
6.6.1 X63 PROFINET SYNC interface.......................................................................... 56
6.6.2 X64.1, X64.2 and X64.3 VISION interface........................................................... 57
6.7 EtherCAT interfaces.............................................................................................. 58
6.7.1 X65 EtherCAT interface........................................................................................ 58
6.7.2 X67.1 and X67.2 EtherCAT bridge interfaces...................................................... 59
6.8 EtherCAT input/output modules............................................................................ 59
6.8.1 Digital I/O modules and bus coupler.................................................................... 60
6.8.2 Bus coupler EK1100.............................................................................................. 61
6.8.3 Infeed EL9100....................................................................................................... 62
6.8.4 16-channel inputs EL1809.................................................................................... 62
6.8.5 16-channel inputs EL1889, negative switching.................................................... 63
6.8.6 4-channel 2 A outputs, EL2024............................................................................ 64
6.8.7 2-channel relay outputs EL2622........................................................................... 65
6.8.8 16-channel outputs EL2809.................................................................................. 65
6.8.9 16-channel outputs EL2889, negative switching.................................................. 66
6.9 EtherCAT gateways............................................................................................... 67
6.9.1 EtherCAT bridge EL6692...................................................................................... 67
6.9.2 EtherCAT bridge EL6695-1001............................................................................. 68
6.9.3 PROFIBUS master/slave EL6731(0010)............................................................... 68
6.9.4 DeviceNet master/slave EL6752(0010)................................................................ 69
6.9.5 VARAN slave bus coupler..................................................................................... 69
6.10 Fast Measurement................................................................................................. 70
6.10.1 X33 Fast Measurement inputs (option)................................................................ 70
6.10.1.1 Power supply for Fast Measurement.................................................................... 70
6.11 VARAN interfaces.................................................................................................. 71
6.11.1 X67.1 and X67.2 VARAN slave interfaces........................................................... 71
6.12 DeviceNet interfaces............................................................................................. 72
6.12.1 DeviceNet interfaces, overview............................................................................. 72
6.12.1.1 X14A and X14B DeviceNet master...................................................................... 73
6.12.1.2 DeviceNet Slave X14C.......................................................................................... 74
6.12.1.3 X14C and X14D DeviceNet interface................................................................... 75
6.13 PROFIBUS interfaces............................................................................................ 76
6.13.1 X15A and X15B PROFIBUS interface.................................................................. 76
6.13.2 X61 PROFIBUS master........................................................................................ 77
6.14 Floating contacts................................................................................................... 78
6.14.1 X31, X32 floating contacts.................................................................................... 78

Optional Interfaces
6.15 Cable inlet X51...................................................................................................... 78

6.16 KLI interfaces......................................................................................................... 79
6.16.1 X66 Ethernet interface (RJ45).............................................................................. 79
6.16.2 X67.1, X67.2 and X67.3 KLI interfaces................................................................ 80
6.16.3 KLI interface on CSP............................................................................................ 81
6.16.4 X17A, X17B, X17C KLI interface.......................................................................... 82
6.16.5 X17D, X17E, X17F KLI interface.......................................................................... 83
6.17 X70 and X71 RoboTeam interface....................................................................... 83
6.17.1 X57 internal power supply.................................................................................... 84
6.18 Euromap interfaces............................................................................................... 85
6.18.1 Overview of E67 interface..................................................................................... 85
6.18.2 Interface E67......................................................................................................... 85
6.18.3 X27 interface......................................................................................................... 87
6.18.4 X62 Profibus and load voltage US1/US2 interface.............................................. 90
6.18.5 X68 interface......................................................................................................... 91
6.19 Performance level.................................................................................................. 91
6.19.1 PFH values of the safety functions...................................................................... 91
7 Maintenance.............................................................................................. 93
7.1 Safety Interface Board Extended.......................................................................... 93
8 KUKA Service........................................................................................... 95
8.1 Requesting support............................................................................................... 95
8.2 KUKA Customer Support...................................................................................... 95
Index 103

Optional Interfaces

Optional Interfaces
Introduction
1 Introduction
1.1 Industrial robot documentation
The industrial robot documentation consists of the following parts:
• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts in KUKA.Xpert
Each of these sets of instructions is a separate document.
1.2 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.
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.

Introduction Optional Interfaces
1.3 Trademarks
• Windows is a trademark of Microsoft Corporation.
• EtherCAT® is a registered trademark and patented tech-

nology, licensed by Beckhoff Automation GmbH, Germany.
• CIP Safety® is a trademark of ODVA.
1.4 Terms used
Term Description
Br M{Number} Brake Motor{Number}
CCU Cabinet Control Unit
CIB Cabinet Interface Board
CIP Safety Common Industrial Protocol Safety
CIP Safety is an Ethernet/IP-based safety inter-
face for connecting a safety PLC to the robot
controller. (PLC = master, robot controller =
slave)
CK Customer-built Kinematics
CSP Controller System Panel
Display element and connection point for USB
and network
Dual NIC Dual Network Interface Card
Dual-port network card
EDS Electronic Data Storage (memory card)
EDS cool Electronic Data Storage (memory card) with ex-
tended temperature range
EMD Electronic Mastering Device
EMC ElectroMagnetic Compatibility
Ethernet/IP Ethernet/Internet Protocol is an Ethernet-based
field bus
HMI Human Machine Interface:
KUKA.HMI is the KUKA user interface.
KCB KUKA Controller Bus
KEB KUKA Extension Bus
KLI KUKA Line Interface
Connection to higher-level control infrastructure
(PLC, archiving)
KONI KUKA Option Network Interface
Interface for KUKA options
KPC KUKA control PC
KPP KUKA Power Pack
Drive power supply with drive controller

Optional Interfaces
Introduction
Term Description
KRL KUKA Robot Language
KUKA programming language
KSB KUKA System Bus
A field bus for internal networking of the con-
trollers
KSI KUKA Service Interface
Interface on the CSP on the control cabinet
The WorkVisual PC can either connect to the
robot controller via the KLI or it can be plugged
into the KSI.
KSP KUKA Servo Pack
Drive controller
KSS KUKA System Software
Manipulator The robot arm and the associated electrical in-
stallations
M{Number} Motor {Number}
NA North America
PELV Protective Extra Low Voltage
External 24 V power supply
PoE Power over Ethernet
QBS Operator safety acknowledgement signal
RDC Resolver Digital Converter (KR C4)
RDC cool Resolver Digital Converter (KR C4) with exten-
ded temperature range
RTS Request To Send
Transmission request signal
SATA connections Data bus for exchanging data between the pro-
cessor and the hard drive
SG FC Servo gun
SIB Safety Interface Board
SION Safety I/O Node
SOP SafeOperation
Option with software and hardware components
PLC A Programmable Logic Controller
is used in systems as a higher-level master
module in the bus system
SRM SafeRangeMonitoring
Safety option with software and hardware com-
ponents
SSB SafeSingleBrake
Safety option
US1 Load voltage (24 V) not switched

Introduction Optional Interfaces
Term Description
US2 Load voltage (24 V) switched. Deactivates ac-
tuators, for example, when the drives are deac-
tivated
USB Universal Serial Bus
Bus system for connecting additional devices to
a computer
EA External axis (linear unit, Posiflex)

Optional Interfaces
Purpose
2 Purpose
2.1 Target group
This documentation is aimed at users with the following knowledge and

skills:
• Advanced knowledge of electrical and electronic systems

• Advanced knowledge of the robot controller
• Advanced knowledge of the Windows operating system
For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about the
training program can be found at www.kuka.com or can be obtained di-
rectly from our subsidiaries.
2.2 Intended use
Use
The following interfaces are options for the KR C4 robot controllers:

• X11 load voltage US1 and US2
• X11 external power supply
• X13 safe digital inputs and outputs for SafeRobot
• X14A/B/C/D DeviceNet M/S incl. load voltages US1/US2
• X14A internal/external power supply for switch
• X14B load voltages US1/US2
• X14B2 load voltages
• X15A and X15B PROFIBUS slave IN and OUT
• X33 Fast Measurement
• X42 reference switch
• X51 four-way cable inlet for digital inputs and outputs
• X53 “Drives ready” lamp interface
• X54 27V PWR US1
• X55 external power supply
• X56 load voltage for PROFINET interface
• X58 external enabling switches
• X61 PROFIBUS master
• X63 PROFINET SYNC
• X64.1, X64.2 and X64.3 KONI via switch
• X65 EtherCAT
• X67.1 and X67.2 EtherCAT bridge master/master
• X67.1 and X67.2 VARAN slave EtherCAT IN/OUT
• KLI interfaces
‒ X66 Ethernet (1xRJ45)
‒ X67.1, X67.2 and X67.3 KLI via switch
‒ CSP extended 2xUSB / RJ45-KSI
‒ X17A/B/C/D/E/F KLI via switch
• X70 and X71 RoboTeam input and output
‒ X57 power supply

Optional Interfaces
The following interfaces are options for the KR C4 midsize robot control-
Purpose
ler:
• E67 Euromap interface
‒ X27 E-STOP and safeguard connection
‒ X51 Wieland four-way cable inlet
‒ X62 PROFIBUS master
‒ X68 Extension Bus
‒ E67 interface for injection molding machines
‒ E67 EtherCAT modules
Misuse
Any use or application deviating from the intended use is deemed to be

impermissible misuse. This includes e.g.:
• Operation outside the permissible operating parameters
• Use in potentially explosive environments

Optional Interfaces
Product description
3 Product description
3.1 Overview of the KR C4 robot controller
The optional interfaces are for the following KR C4 robot controllers:
• KR C4
• KR C4 CK
• KR C4 midsize
• KR C4 midsize CK
• KR C4 extended
• KR C4 extended CK
Fig. 3-1: Overview of robot controllers
1 KR C4; KR C4 CK
2 KR C4 midsize; KR C4 midsize CK
3 KR C4 extended; KR C4 extended CK
4 Lower connection panel
5 Upper side connection panel
3.2 Optional interfaces, connection panel
Overview
The connection panel of the robot controller consists of connections for

the following cables:
• Power cable / infeed
• Motor cables to the manipulator
• Data cables to the manipulator
• KUKA smartPAD cable
• PE cables
• Peripheral cables
The configuration of the connection panel varies according to the custom-
er-specific version and the options required.

Product description Optional Interfaces
3.3 Lower connection panel
Overview
Fig. 3-2: Lower connection panel
1 Slot 1 (>>> "Assignment of slot 1" Page 14)

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.
Assignment of slot 1
Slot 1 can be assigned the following interfaces:

Slot Connector Description Comment
X51 Wieland four-way cable -
inlet for digital inputs/
outputs
X70 RoboTeam input -

X71 RoboTeam output
X57 Infeed, PS2 external -

X71 RoboTeam output
X53 “Drives ready” lamp -
X53 “Drives ready” lamp -

Optional Interfaces
Product description
X71 RoboTeam output
X54 27V PWR US1 X54 can be selected
individually

X71 RoboTeam output
X14B 4-pole X14B can be selec-
ted individually
• 27V PWR NA
US1/US2
• 24V PWR NA
US1/US2
5-pole
• 27V PWR US1/US2

• 27V PWR US1
X71 RoboTeam output
X58 External enabling switch X58 can be selected
individually

X71 RoboTeam output
X33 Fast measurement X33 can be selected
individually

X13 Safe digital inputs and -
outputs for SafeRobot

outputs
X56 Load voltages X56 can be selected

individually
individually


X53 “Drives ready” lamp X53 can be selected
individually
individually
X54 27 V PWR US1 X54 can be selected

individually
individually

individually
individually
X14A 4-pole X14A can be selec-

ted individually
• 27 V PWR IN NA
5-pole
• 27 V PWR IN
ted individually
• 24 V PWR NA
US1/US2
• 24 V PWR NA
US1/US2
5-pole
• 27 V PWR US1/US2
• 27 V PWR US1
individually
X31 US 2 floating contact X31 and X32 can
X32 US 2 floating contact only be selected in
combination with
X14A and X14B
X14A External 24 V supply X14A and X14B
must be selected to-
4-pole
gether
• 24 V PWR IN
X14B Load voltage
4-pole
• 24 V PWR IN NA
US1/US2

Optional Interfaces
Product description
X14A External 24 V supply X14A and X14B
must be selected to-
4-pole
gether
• 24 V PWR IN NA
US1/US2
X14B Load voltage
4-pole
• 24 V PWR IN NA
US1/US2
individually
ted individually
• 24 V PWR NA
US1/US2
X31 US 2 floating contact X31 can be selected
individually
individually
X53 “Drives ready” lamp X53 can be selected
individually
X14B 4-pole -
• 24 V PWR US1/US2
X14B2 4-pole -
• 24 V PWR

X11 • Digital safety -
• Ext. power supplies
• Load voltages
• EMERGENCY STOP
devices on the robot
controller
individually
X55 External power supplies X55 can be selected
individually

outputs


X17A KUKA Line Interface via M12 D-coded
switch
X17B KUKA Line Interface via
switch
X17C KUKA Line Interface via
switch

X61 PROFIBUS master X61 can be selected
individually
X15A PROFIBUS slave IN -
X15B PROFIBUS slave OUT -
X67.1 KUKA Line Interface via RJ 45

switch
switch
switch
X65 KUKA Extension Bus X65 can be selected
individually
X66 KUKA Line Interface X66 can be selected
individually

individually
individually
X14A DeviceNet master -

X14B Load voltages -
X14C DeviceNet slave -
X14A DeviceNet master -

X14B Load voltages -
individually

individually
individually

Optional Interfaces
Product description
outputs

individually
X63 PNET-SYNC X63 can be selected
individually
X67.1 • VARAN slave Ether- Signal IN

CAT
• EtherCAT bridge
(master/master)
X67.2 • VARAN slave Ether- Signal OUT
CAT
• EtherCAT bridge
(master/master)
X55 External power supplies • VARAN slave
EtherCAT
• EtherCAT bridge
(master/master)
individually
X63 PNET-SYNC X63 can be selected
individually
X17D KUKA Line Interface via M12 D-coded

switch
X17E KUKA Line Interface via
switch
X17F KUKA Line Interface via
switch

individually
individually

individually
individually


X14C DeviceNet slave IN -
X14D DeviceNet slave OUT -
X33 Fast measurement -
X64.1 KONI via switch -


switch
switch
switch
X67.1 • VARAN slave Ether- Signal IN
CAT
• EtherCAT bridge
(master/master)
X67.2 • VARAN slave Ether- Signal OUT
CAT
• EtherCAT bridge
(master/master)
X55 External power supplies • VARAN slave
EtherCAT
• EtherCAT bridge
(master/master)
X17A KUKA Line Interface via M12 D-coded
switch
X17B KUKA Line Interface via
switch
X17C KUKA Line Interface via
switch
Slot 6 is assigned the following interfaces:

Slot Connector Description Comments
X21.1 RDC2 connection KR C4 extended on-
ly
X19 smartPAD connection -
X21 RDC1 connection -
X42 Mastering probe for Safe- X42 can be selected
Robot optionally.

Optional Interfaces
Product description
3.4 E67 interface, upper side connection panel
Overview
Fig. 3-3: E67 connection panel
1 Blanking plate
Slot 12 is assigned the following interface:

X51 Wieland four-fold cable -
outputs
Slot 13 is assigned the following interfaces:

individually.
individually.

X27 EMERGENCY STOP and -
safeguards


E67 Interface to injection -
molding machines
3.5 KLI/KSI interfaces
CSP interface
Fig. 3-4: KLI and KSI interfaces on CSP
1 KLI/KSI interface (optional)
Switch overview
The following switch variants can be used for the KLI interface:
• 5-port switch (not deterministic, not manageable) for standard Ethernet
applications.
• 8-port switch (e.g. deterministic and manageable) for Ethernet applica-
tions.
The 24 V power supply to the switch can optionally be internal or
external. The power supply to the switch is via X11 for preference. If X11
has not been configured, the power supply is via connector X55.
No switch is required for the KSI interface.
3.6 Digital I/O modules and bus coupler
3.6.1 Digital I/O modules 16/16
Overview
The digital I/O interface 16/16 consists of the following components:

• EtherCAT bus coupler
• EtherCAT 16x input terminal

Optional Interfaces
Product description
• EtherCAT 16x output terminal
• EtherCAT bus end cap
Fig. 3-5: Overview of digital modules 16/16
1 KEI connection X1
2 EK1100 EtherCAT bus coupler A20
3 EL1809/ EL1889 input terminal A21
4 EL2809/ EL2889 output terminal A22
5 EL9011 bus end cap
Detailed information about the EtherCAT bus coupler and the I/O mod-
ules can be found in the manual from Beckhoff.
3.6.2 Digital I/O modules 16/16/4
Overview
The digital I/O interface 16/16/4 consists of the following components:

• EtherCAT infeed terminal

Fig. 3-6: Digital module 16/16/4
1 KEI connection X1
2 EK1100 bus coupler A20
5 EL9100 infeed terminal A23
6 EL2024 output terminal A27
3.6.3 Digital I/O interface 32/32/4
Overview
The digital I/O interface 32/32/4 consists of the following components:


Optional Interfaces
Product description
Fig. 3-7: Digital modules 32/32/4
1 KEI connection X1
2 EK1100 EtherCAT bus coupler A20
3.6.4 EtherCAT modules and switching devices, E67 interface
Overview
The digital I/O interface for the E67 interface consists of the following
components:
• PROFIBUS master
• PROFIBUS slave
• EtherCAT 2x relay output terminal

Fig. 3-8: Overview of EtherCAt modules
1 EK1100 EtherCat bus coupler A30

2 EL6731 PROFIBUS master (optional) A31
3 EL6731-0010 PROFIBUS slave (optional) A32
5 EL1809 input terminal A34
7 EL2622 relay output terminal A36
11 F41 blowout fuse
12 K20 switching device, EMERGENCY STOP
13 K20.1 switching device, EMERGENCY STOP
14 K21 switching device, operator safety
15 K21.1 switching device, operator safety
Fuse rating
Item Fuse Value Designation

11 F41 2 A External power supply
3.7 Low-voltage power supply unit
Description
The low-voltage power supply unit provides 24 V /10 A, e.g. for load vol-
tages US1 and US2.

Optional Interfaces
Product description
Fig. 3-9: Low-voltage power supply unit
1 Potentiometer for setting the output voltage
3.8 Safety Interface Board
Description
The Safety Interface Board (SIB) is an integral part of the safety interface.
2 different SIBs are used in the robot controller, the Standard SIB and the
Extended SIB, depending on the configuration of the safety interface. The
Standard SIB and the Extended SIB incorporate sensing, control and
switching functions. The Extended SIB can only be operated together with
the Standard SIB. The output signals are provided as electrically isolated
outputs.
The Standard SIB contains the following safe inputs and outputs:
• 5 safe inputs
• 3 safe outputs
The Extended SIB contains the following safe inputs and outputs:
• 8 safe inputs
• 8 safe outputs
Functions
The Standard SIB has the following functions:

• Safe inputs and outputs for the discrete safety interface of the robot
controller
The Extended SIB has the following functions:
• Safe inputs and outputs for range selection and range monitoring for
the SafeRobot option
or optionally
• Provision of signals for axis range monitoring
3.9 24 V external power supply
External 24 V power supply is possible via the following interfaces:

• RoboTeam X57
• Interface X11
• Connector X55
Power supply to the KLI switch in the robot controller

Optional Interfaces
The external power supply to the SIB and CIB boards cannot be isolated.
Product description
If the SIB is supplied externally, the CIB is also supplied externally, and
vice versa.

Optional Interfaces
Technical data
4 Technical data
4.1 Safety Interface Board Extended
SIB outputs
The power contacts must only be fed from a safely isolated PELV
power supply unit. (>>> 4.3 "External 24 V power supply" Page 30)
Operating voltage, power contacts ≤ 30 V

Current via power contact min. 10 mA
< 750 mA
Cable lengths (connection of ac- < 50 m cable lengths
tuators)
< 100 m wire length (outgoing and
incoming lines)
Cable cross-section (connection of ≥ 1 mm2
actuators)
Switching cycles, Standard SIB Service life: 20 years
< 100,000 (corresponds to 13
switching cycles per day)
Switching cycles, Extended SIB Service life: 20 years
< 780,000 (corresponds to 106
switching cycles per day)
The module must be exchanged when the number of switching cycles is
exceeded.
SIB inputs
Switching level of the inputs The state for the inputs is not de-
fined for the voltage range from
5 V to 11 V (transition range). Ei-
ther the ON state or the OFF state
is set.
OFF state for the voltage range
from -3 V to 5 V (OFF range).
ON state for the voltage range
from 11 V to 30 V (ON range).
Load current with 24 V supply volt- > 10 mA
age
Load current with 18 V supply volt- > 6.5 mA
age
Max. load current < 15 mA
Cable length, terminal - sensor < 50 m, or < 100 m wire length
(outgoing and incoming lines)
Cable cross-section, test output - > 0.5 mm2
input connection
Capacitive load for the test outputs < 200 nF
per channel
Resistive load for the test outputs < 33 Ω
per channel

Technical data Optional Interfaces
Test outputs A and B are sustained short-circuit proof.

The specified currents flow via the contact element connected to the in-
put. This must be rated for the maximum current of 15 mA.
4.2 Low-voltage power supply unit 24 V/10 A
Rated output voltage 24 V DC

Tolerance for rated output voltage ±1%
Setting range for rated output volt- 22.5 V - 29.5 V
age
Condition on delivery 24 V DC
4.3 External 24 V power supply
PELV external power supply
External voltage PELV power supply unit acc. to

EN 60950 with rated voltage 27 V
(18 V ... 30 V), safely isolated
Continuous current > 8 A
Cable cross-section of power sup- ≥ 1 mm2
ply cable
Cable length of power supply cable < 50 m, or < 100 m wire length
(outgoing and incoming lines)
The cables of the power supply unit must not be routed together with
power-carrying cables.
The minus connection of the external voltage must be grounded by the

customer.
Parallel connection of a basic-insulated device is not permitted.

Optional Interfaces
Safety
5 Safety
This documentation contains safety instructions which refer specifically to
the product described here. The fundamental safety information for the in-
dustrial robot can be found in the “Safety” chapter of the operating or as-
sembly instructions for the robot controller.
WARNING
The “Safety” chapter in the operating instructions or assembly instruc-
tions of the robot controller must be observed. Death to persons, severe
injuries or considerable damage to property may otherwise result.

Safety Optional Interfaces

Optional Interfaces
Planning
6 Planning
Overview
Step Description Information

1 Load voltage US1 and US2 (>>> 6.4.1 "X11 load voltage
interface X11 US1/US2" Page 47)
2 External power supply via in- (>>> 6.2.1 "X11 external
terface X11 power supply" Page 45)
3 Check US2 function of load (>>> 6.4.4 "Checking the
voltage contactors US2 function, load voltage
contactor" Page 49)
4 SafeRobot interface X13 (>>> 6.1.1 "X13 SafeOpera-
tion interface" Page 34)
5 DeviceNet interface X14A (>>> 6.12.1 "DeviceNet inter-
faces, overview" Page 72)
6 27V PWR IN NA interface (>>> 6.5.1 "X14A interface
X14A 27V PWR IN NA" Page 54)
7 27V PWR IN interface X14A (>>> 6.5.2 "X14A interface
27V PWR IN" Page 55)
8 27V PWR US1/US2 inter- (>>> 6.4.5 "X14B interface
face X14B 27V PWR US1/US2"
Page 50)
9 27V PWR US1 interface (>>> 6.4.6 "X14B interface
X14B 27V PWR US1" Page 51)
10 27V PWR NA US1/US2 in- (>>> 6.4.7 "X14B interface
terface X14B 27V PWR NA US1/US2"
Page 52)
11 24V PWR NA US1/US2 in- (>>> 6.4.8 "X14B interface
terface X14B 24V PWR NA US1/US2"
Page 52)
12 PROFIBUS interface X15A (>>> 6.13.1 "X15A and
and X15B X15B PROFIBUS interface"
Page 76)
13 Fast Measurement interface (>>> 6.10.1 "X33 Fast Meas-
X33 urement inputs (option)"
Page 70)
14 Mastering probe SafeRobot (>>> 6.1.3 "X42 reference
interface X42 switch" Page 43)
15 Cable inlet interface X51 (>>> 6.15 "Cable inlet X51"
Page 78)
16 “Drives ready” lamp interface (>>> 6.1.2 "X53 “Drives
X53 ready” lamp" Page 43)
17 27V PWR US1 interface X54 (>>> 6.4.3 "X54 interface
27V PWR US1" Page 49)
18 External power supply inter- (>>> 6.2.2 "X55 external
face X55 power supply" Page 46)
19 Load voltage US1 and US2 (>>> 6.4.2 "X56 load voltag-
interface X56 es US1/US2" Page 48)
20 External enabling interface (>>> 6.1.4 "X58 external en-
X58 abling switches" Page 43)

Planning Optional Interfaces

21 PROFIBUS master interface (>>> 6.13.2 "X61
X61 PROFIBUS master"
Page 77)
22 PROFINET SYNC interface (>>> 6.6.1 "X63 PROFINET
X63 SYNC interface" Page 56)
23 KONI interfaces X64.1, (>>> 6.6.2 "X64.1, X64.2
X64.2 and X64.3 and X64.3 VISION interface"
Page 57)
24 KUKA Extension Bus inter- (>>> 6.7.1 "X65 EtherCAT
face X65 interface" Page 58)
25 VARAN slave EtherCAT (>>> 6.11.1 "X67.1 and
X67.2 VARAN slave interfa-
ces" Page 71)
26 EtherCAT bridge (master/ (>>> 6.7.2 "X67.1 and X67.2
master) EtherCAT bridge interfaces"
Page 59)
27 KLI interfaces (>>> 6.16 "KLI interfaces"
Page 79)
28 RoboTeam interface X70 (>>> 6.17 "X70 and X71 Ro-
and X71 boTeam interface" Page 83)
RoboTeam start-up jumpers
X57
29 Digital I/O modules and bus (>>> 6.8.1 "Digital I/O mod-
coupler ules and bus coupler"
Page 60)
30 E67 interface (>>> 6.18.1 "Overview of
E67 interface" Page 85)
31 Performance level (>>> 6.19 "Performance lev-
el" Page 91)
6.1 Discrete interfaces for safety options
6.1.1 X13 SafeOperation interface
Description
Discrete interface X13 can be used for the following technology packages:
• KUKA.SafeRangeMonitoring
• KUKA.SafeOperation
• KUKA.SafeSingleBrake
It is only possible to use the discrete interface for safety options if the
technology package SafeRangeMonitoring, SafeOperation or SafeSingle-
Brake is installed and the interface has been configured using the tech-
nology package. Configuration of the interface is described in the Safe-
RangeMonitoring, SafeOperation or SafeSingleBrake documentation.

Optional Interfaces
Planning
It is only possible to use the discrete interface for safety options if the
technology package SafeRangeMonitoring, SafeOperation or SafeSingle-
Brake is installed and the interface has been configured using the tech-
nology package. Configuration of the interface is described in the Safe-
RangeMonitoring, SafeOperation or SafeSingleBrake documentation.
Contact diagram
Fig. 6-1: Contact diagram, view from contact side
Necessary equipment
• Mating connector: Han 108DD with a male insert

• Housing size: 24B
• Cable gland M32
• Cable diameter 14-21 mm
• Recommended cable cross-section 0.75 mm2
6.1.1.1 X13 SafeOperation interface
The X13 safety interface is wired internally to the SIB extended.
Connector pin allocation X13, inputs
The technical data for the inputs can be found in the section (>>> "SIB
inputs" Page 29).
Pin Description Function
1/3/5/ Test output A Makes the pulsed voltage
7/9/11 available for the individual in-
(test signal)
/13/15 terface inputs of channel A.
19/21/ Test output B Makes the pulsed voltage
23/25/ available for the individual in-
(test signal)
27/29/ terface inputs of channel B.
31/33
2 Reduced velocity channel A -
4 Monitoring space 12, channel -
A
6 Monitoring space 13, channel Programmable to SBH 3 chan-
A nel A in WorkVisual (only un-
der KSS 8.3)
der KSS 8.3)
der KSS 8.3)
der KSS 8.3)


14 Safe operational stop, axis -
group 1, channel A
group 2, channel A
20 Reduced velocity, channel B -
22 Monitoring space 12, channel -
B
B nel B in WorkVisual (only un-
der KSS 8.3)
der KSS 8.3)
der KSS 8.3)
der KSS 8.3)
group 1, channel B
group 2, channel B
In the cabling for the input signals and test signals in the system, suita-
ble measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of input signals and test signals).
Connector pin allocation X13, outputs
The technical data for the outputs can be found in the section (>>> "SIB
outputs" Page 29).
Pin Description
37 MR1 alarm space input, channel A
38 MR1 alarm space output, channel A
49 Safe monitoring active, input, channel A
50 Safe monitoring active, output, channel A
51 RR robot referenced, input, channel A

Optional Interfaces
Planning
Pin Description
52 RR robot referenced, output, channel A
55 MR1 alarm space input, channel B
56 MR1 alarm space output, channel B
67 Safe monitoring active, input, channel B
68 Safe monitoring active, output, channel B
69 RR robot referenced, input, channel B
70 RR robot referenced, output, channel B
In the cabling for the output signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the output signals of a channel (e.g. separate cabling).
6.1.1.2 X13 SafeRangeMonitoring interface
inputs" Page 29).
(test signal)
19/21/ Test output B Makes the clocked voltage
(test signal)
31/33
2 Spare -
4 Spare -
6 Spare -
8 Spare -
10 Spare -
12 Spare -
14 Spare -
16 Spare -
20 Spare -
22 Spare -


24 Spare -
26 Spare -
28 Spare -
30 Spare -
32 Spare -
34 Spare -
outputs" Page 29).
Pin Description
51 RR robot referenced, input, channel A
52 RR robot referenced, output, channel A

Optional Interfaces
Planning
Pin Description
69 RR robot referenced, input, channel B
70 RR robot referenced, output, channel B
6.1.1.3 X13 SafeSingleBrake interface
inputs" Page 29).
(test signal)
19/21/ Test output B Makes the pulsed voltage
(test signal)
31/33
2 Spare -
4 Spare -
group 3, channel A
group 4, channel A
group 5, channel A
group 6, channel A
group 1, channel A
group 2, channel A
20 Spare -
22 Spare -
group 3, channel B
group 4, channel B
group 5, channel B
group 6, channel B
group 1, channel B
group 2, channel B

outputs" Page 29).
Pin Description
37 Spare
38 Spare
39 Spare
40 Spare
41 Spare
42 Spare
43 Spare
44 Spare
45 Spare
46 Spare
47 Spare
48 Spare
51 Spare
52 Spare
55 Spare
56 Spare
57 Spare
58 Spare
59 Spare
60 Spare
61 Spare
62 Spare
63 Spare
64 Spare
65 Spare
66 Spare
69 Spare
70 Spare

Optional Interfaces
6.1.1.4 Wiring examples for safe inputs and outputs
Planning
Safe input
The switch-off capability of the inputs is monitored cyclically.

The inputs of the SIB are of dual-channel design with external testing.
The dual-channel operation of the inputs is monitored cyclically.
The following diagram illustrates the connection of a safe input to a float-
ing contact provided by the customer.
Fig. 6-2: Connection schematic for safe input
1 Safe input, SIB

2 SIB/CIB
3 Robot controller
4 Interface X11 or X13
5 Test output channel B
6 Test output channel A
7 Input X, channel A
8 Input X, channel B
9 System side
10 Floating contact
Test outputs A and B are fed with the supply voltage of the SIB. Test out-
puts A and B are sustained short-circuit proof. The test outputs must only
be used to supply the SIB inputs, and for no other purpose.
The wiring example described can be used to achieve compliance with
Category 3 and Performance Level (PL) d according to EN ISO 13849-1.
Dynamic testing
• The switch-off capability of the inputs is tested cyclically. For this, the
test outputs TA_A and TA_B are switched off alternately.
• The switch-off pulse length is defined for the SIBs as t1 = 625 μs (125
μs – 2.375 ms).
• The duration t2 between two switch-off pulses on one channel is
106 ms.
• The input channel SIN_x_A must be supplied by the test signal TA_A.
The input channel SIN_x_B must be supplied by the test signal TA_B.
No other power supply is permissible.
• It is only permitted to connect sensors which allow the connection of
test signals and which provide floating contacts.
• The signals TA_A and TA_B must not be significantly delayed by the
switching element.

Switch-off pulse diagram
Fig. 6-3: Switch-off pulse diagram, test outputs
t1 Switch-off pulse length

t2 Switch-off period per channel (106 ms)
t3 Offset between switch-off pulses of both channels
(53 ms)
TA/A Test output channel A
TA/B Test output channel B
SIN_X_A Input X, channel A
SIN_X_B Input X, channel B
Safe output
On the SIB, the outputs are provided as dual-channel floating relay out-
puts.
The following diagram illustrates the connection of a safe output to a safe
input provided by the customer with external test facility. The input used
by the customer must be monitored externally for cross-connection.
Fig. 6-4: Connection schematic for safe output
1 SIB
2 Robot controller
3 Interface X11 or X13
4 Output wiring
5 System side
6 Safe input (Fail Safe PLC, safety switching device)
7 Test output channel B

Optional Interfaces
Planning
8 Test output channel A
9 Input X, channel A
10 Input X, channel B
The wiring example described can be used to achieve compliance with
Category 3 and Performance Level (PL) d according to EN ISO 13849-1.
6.1.2 X53 “Drives ready” lamp
Necessary equipment
• Female and male connector, 5-pole
Fig. 6-5: Contact diagram
Connector pin allocation X53
Pin Description
1 PE
2 +24 V “Drives ready” lamp / 2 A (F53)
3 0 V “Drives ready” lamp
6.1.3 X42 reference switch
Description
The reference switch X42 is needed to carry out the mastering test.
Detailed information about the mastering test can be found in the KU-
KA.SafeOperation documentation.
Pin Description
1 TA24V A
2 E_REF_A_24V
3 GND
4 TA24V B
5 E_REF_B_24V
6.1.4 X58 external enabling switches
Description
Interface X58 is used for connecting external enabling switches.

Necessary equipment
• Article 00277097 enabling switch at X58 with L = 20 type: 2-channel

enabling switch with 20 m connecting cable including Han 8D-F con-
nector
• Recommended wire cross-section: 0.75 mm2
For connection of the external 2-channel enabling switch 1 with floating

contacts.
NOTICE
An external enabling switch 2 is not connected. For this reason, pins
3/6 and 2/7 are jumpered in the connector and only effective in the test
operating modes.

3 Test output A Makes the pulsed voltage
4 available for the individual in-
(test signal)
terface inputs of channel A.
7 Test output B Makes the clocked voltage
8 available for the individual in-
(test signal)
terface inputs of channel B.
5 External enabling 1 channel A For connection of an external
1 External enabling 1 channel B 2-channel enabling switch 1
with floating contacts.
If no external enabling switch
1 is connected, pins 1/8 and
4/5 must be jumpered. Only
effective in TEST modes.
6 External enabling 2 channel A For connection of an external
2 External enabling 2 channel B 2-channel enabling switch 2
with floating contacts.
If no external enabling switch
2 is connected, pins 3/6 and
2/7 must be jumpered. Only
effective in TEST modes.
Function of external axis enabling switch
• External enabling 1
Enabling switch must be pressed for jogging in T1 or T2. Input is
closed.

Optional Interfaces
Planning
• External enabling 2
Enabling switch is not in the panic position. Input is closed.
• If a smartPAD is connected, its enabling switches and the external en-
abling are ANDed.
Function External ena- External ena-

Switch position
(only active for T1 and T2) bling 1 bling 2
Safety stop 1 (drives switched off Input open Input open No operational
when axis at standstill) state
Safety stop 2 (safe operational stop, Input open Input closed Not pressed
drives switched on)
Safety stop 1 (drives switched off Input closed Input open Panic position
when axis at standstill)
Axes enabled (axis jogging possible) Input closed Input closed Center position
6.2 External power supplies
6.2.1 X11 external power supply
Description
The external power supply via X11 can be used, for example, for external
power supply to a switch.
Necessary equipment

• Cable gland M32
• Cable cross-section ≥ 1 mm2
Contact diagram
Connector pin allocation
Pin Description
105 +24 V external
106 0 V external
107 +24 V internal
108 0 V internal
For internal power supply, pins 105 and 107 and pins 106 and 108 must
be jumpered.

6.2.2 X55 external power supply
Description
The following couplers can be externally supplied with power via interface
X55:
• Switch
• VARAN slave
• EtherCAT bridge
Necessary equipment
• Male insert, HAN 8D
• Cable clamping range: Ø9 ... Ø13 mm

• Recommended wire cross-section: 1 mm2
Pin Description
5 +24 V external
6 0 V external
7 +24 V internal
8 0 V internal
6.3 Low-voltage power supply unit 24 V/10 A
Description
The low-voltage power supply unit provides 24 V/10 A. The following com-
ponents, for example, can be supplied with power by the low-voltage pow-
er supply unit:
• Switch
• X14B and X14B2 interfaces
• X53 “Drives ready” lamp
NOTICE
All components connected to the low-voltage power supply unit must
not exceed a maximum current of 10 A in total. This may result in dam-
age to components, the tool or the robot.

Optional Interfaces
Planning
6.4 Load voltages
6.4.1 X11 load voltage US1/US2
Description
In the case of interfaces with load voltage US1/US2, load voltage US1 is
not switched and US2 is implemented as switchable using safe technology
so that actuators, for example, are switched off when the drives are deac-
tivated.
This function exists in the following three variants and is set in the safety
configuration:
• Switched by an external PLC:
The contactor is switched directly by an external input (US2 signal in
the PROFIsafe/CIP Safety/FSoE telegram). This variant is available
only if PROFIsafe/CIP Safety/FSoE is in use.
• Switched by the KRC:
The contactor is switched if the “FF signal” and the non-safe
“US2_CONTACTOR_ON” signal from the robot controller are set. In
this way, the non-safe part of the robot controller can also switch the
contactor.
• Deactivated:
The contactor is always off.
If, due to a fault in the system cabling, there is a cross connection be-
tween US1 and US2, this will not be noticed during normal operation. The
result is that load voltage US2 is no longer switched off which can lead to
a dangerous state in the system.
In the cabling for the two voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the vol-
tages (e.g. separate cabling of US1 and US2 or a cable with reinforced
insulation between the two voltages).
The function of the load voltage contactors must be checked in accord-

ance with (>>> 6.4.4 "Checking the US2 function, load voltage contac-
tor" Page 49).
If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.
Contact diagram
Necessary equipment

• Cable gland M32
• Cable cross-section ≥ 1 mm2

Pin Signal Description

91 Load voltage US1 24 V internal / 5 A non-switch-
ed
The voltage is switched on as
long as the controller is sup-
plied with voltage.
92 0 V internal
93 Load voltage US2 24 V internal / 7 A switched
(>>> "Description" Page 47)
94 0 V internal
Load voltage US2 is switched via contactors Q5 and Q6. Fuses F6 (US1)
and F301 (US2) are located on the CCU.
6.4.2 X56 load voltages US1/US2
Description
In the case of interfaces with load voltage US1/US2, load voltage US1 is
not switched and US2 is implemented as switchable using safe technology
so that actuators, for example, are switched off when the drives are deac-
tivated.
This function exists in the following three variants and is set in the safety
configuration:
• Switched by an external PLC:
The contactor is switched directly by an external input (US2 signal in
the PROFIsafe/CIP Safety/FSoE telegram). This variant is available
only if PROFIsafe/CIP Safety/FSoE is in use.
• Switched by the KRC:
The contactor is switched if the “FF signal” and the non-safe
“US2_CONTACTOR_ON” signal from the robot controller are set. In
this way, the non-safe part of the robot controller can also switch the
contactor.
• Deactivated:
The contactor is always off.

tor" Page 49).

Optional Interfaces
Planning
Necessary equipment
• Male insert, Han Q7/0

Contact diagram
Pin Description
1 US1 +24 V / 5 A (F6)
2 US1 0 V
3 US2 +24 V / 7 A (F301)
4 US2 0 V
- PE
Load voltage US2 is switched via contactors Q5 and Q6. The fuses are
located on the CCU.
6.4.3 X54 interface 27V PWR US1
Description
Interface X54 provides the unswitched load voltage US1.
Necessary equipment
• Male insert, Han Q7/0

Contact diagram
Pin Description
1 US1 +24 V / 5 A (F6)
2 US1 0 V
6.4.4 Checking the US2 function, load voltage contactor
The US2 function must be checked in the following cases:

• Following initial start-up or recommissioning of the industrial robot

• After a change to the industrial robot
• After a change to the safety configuration
• After a software update, e.g. of the System Software
• After the load voltage contactors have been exchanged
• The check must be carried out at least once a year.
Procedure
• PROFIsafe or CIP Safety:

Set US2 input; contactor switches on.
Reset US2 input; contactor switches off.
• Automatic:
Press enabling switch; contactor switches on; manipulator can be
moved.
Release enabling switch; contactor switches off.
• Deactivated:
In this configuration, it is not necessary to check the US2 contactor.
The outputs must not be used.
External PLC
In this configuration, the US2 contactor can be checked by deactivating

the input “Peripheral contactor (US2)” in the PROFIsafe or CIP Safety
telegram.
KRC
In this configuration, the US2 contactor can be checked by opening the

operator safety device (safeguard) in “Automatic” or “Automatic External”
mode and releasing the enabling switch in “T1” or “T2” mode.
6.4.5 X14B interface 27V PWR US1/US2

tor" Page 49).
Necessary equipment
• Connector, 7/8" 5-pole

• Maximum cable cross-section: AWG16

Optional Interfaces
Planning
Contact diagram
Connector pin allocation X14B
Pin Description
2 US1 +24 V / 5 A
4 US1 0 V
3 PE
1 US2 +24 V / 7 A
5 US2 0 V
located on the CCU.
6.4.6 X14B interface 27V PWR US1
Description
The interface is used for the external power supply.
Necessary equipment

Contact diagram
Pin Description
2 US1 +24 V / 5 A
4 US1 0 V
3 PE
The fuses are located on the CCU.

6.4.7 X14B interface 27V PWR NA US1/US2

tor" Page 49).
Necessary equipment

Pin Description
2 US1 +24 V / 5 A
3 US1 0 V
1 US2 +24 V / 7 A
4 US2 0 V
located on the CCU.
6.4.8 X14B interface 24V PWR NA US1/US2

tor" Page 49).

Optional Interfaces
Planning
Necessary equipment

Contact diagram
Pin Description
1 +24 V US2
2 +24 V US1
3 0 V US1
4 0 V US2
Load voltage US2 is switched via contactors Q5 and Q6. Fuse protection
is implemented by means of fuse terminals.
6.4.9 X14B2 and X14B interface 24 V PWR US1/US2
Description
The interface is used for the external power supply.


tor" Page 49).
Contact diagram

Necessary equipment

Pin Description
1 +24 V US2 / 4 A
2 +24 V US1 / 4 A
3 0 V US1
4 0 V US2
Connector pin allocation X14B2
Pin Description
1 +24 V / 5 A
2 +24 V / 5 A
3 0 V
4 0 V
Fuse protection is implemented by means of fuse terminals.
6.5 Infeed
6.5.1 X14A interface 27V PWR IN NA
Description
Interface X14A is used for the internal and external power supply of the
internal switch.
Necessary equipment


Optional Interfaces
Planning
Connector pin allocation X14A
Pin Description
1 24V external
2 0 V external
4 24V internal
3 0V internal
6.5.2 X14A interface 27V PWR IN
Description
internal switch.
Necessary equipment

Pin Description
1 24V external
2 0 V external
3 PE
4 24V internal
5 0V internal
6.5.3 X14A interface 24V PWR IN NA
Description
internal switch.
Necessary equipment
• Connector 7/8" 4-pole


Pin Description
2 24V internal
3 0V internal
6.6 Ethernet interfaces
6.6.1 X63 PROFINET SYNC interface
Description
The interface PROFINET SYNC X63 is connected to the KUKA Line Inter-
face (KLI) on the control PC via the interface module IM151-3 PN (A80)
and enables synchronization with an external controller.
Necessary equipment
• Connector RJ45
• Recommended connecting cable: PROFINET-compatible, min. catego-
ry CAT 5e
Pin assignment
Fig. 6-20: Pin assignment

Optional Interfaces
Planning
Pin Description
1 TD+
2 TD-
3 RD+
6 RD-
- PE
6.6.2 X64.1, X64.2 and X64.3 VISION interface
Description
The interfaces X64.1, X64.2 and X64.3 are connected to the KUKA KONI
Interface (KONI) on the control PC via a PoE switch.
Necessary equipment
• Connector RJ45
• Recommended connecting cable: Ethernet-compatible, min. category
CAT 6
Pin assignment
Connector pin allocation X64.1, X64.2 and X64.3
Pin Description
1 TD+
2 TD-
3 RD+
6 RD-
4 C+
5 C-
7 D+
8 D-

6.7 EtherCAT interfaces
6.7.1 X65 EtherCAT interface
Description
EtherCAT slaves outside the robot controller are connected via interface
X65. The EtherCAT line is routed out of the robot controller.
Interface X65 can be wired internally to the CCU, either directly or via a
bus coupler.
The EtherCAT devices must be configured with WorkVisual.
Necessary equipment
• RJ45 connector
• Recommended connecting cable: PROFINET-compatible, min. catego-

ry CAT 5e
Connector pin allocation X65 via CIB
Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
6 TPFI_N
Connector pin allocation X65 via bus coupler
Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
6 TPFI_N

Optional Interfaces
Planning
6.7.2 X67.1 and X67.2 EtherCAT bridge interfaces
Description
EtherCAT bridge interfaces X67.1 and X67.2 enable communication be-

tween an EtherCat master and the robot controller via the EtherCat
bridge.
Necessary equipment
• Connector V14 RJ45

CAT 5e
Connector pin allocation X67.1
Pin Description
1 TD+ Master IN
2 TD- Master IN
3 RD+ Master IN
6 RD- Master IN
- PE
Pin Description
1 TD+ Master OUT
2 TD- Master OUT
3 RD+ Master OUT
6 RD- Master OUT
- PE
6.8 EtherCAT input/output modules

6.8.1 Digital I/O modules and bus coupler
Overview

1 EK1100 bus coupler (>>> 6.8.2 "Bus coupler
EK1100" Page 61)
2 EL9100 infeed (>>> 6.8.3 "Infeed EL9100"
Page 62)
3 EL1809 16-channel inputs (>>> 6.8.4 "16-channel inputs
EL1809" Page 62)
4 EL1889 16 channel input, (>>> 6.8.5 "16-channel inputs
negative switching EL1889, negative switching"
Page 63)
5 EL2024 4-channel 2 A out- (>>> 6.8.6 "4-channel 2 A
puts outputs, EL2024" Page 64)
6 EL2622 2-channel 5 A relay (>>> 6.8.7 "2-channel relay
outputs outputs EL2622" Page 65)
7 EL2809 16-channel 0.5 A (>>> 6.8.8 "16-channel out-
outputs puts EL2809" Page 65)
8 EL2889 16 channel output, (>>> 6.8.9 "16-channel out-
negative switching puts EL2889, negative switch-
ing" Page 66)
9 EL6692 EtherCAT bridge (>>> 6.9.1 "EtherCAT bridge
EL6692" Page 67)
10 EL6695 EtherCAT bridge (>>> 6.9.2 "EtherCAT bridge
EL6695-1001" Page 68)
11 EL6731 PROFIBUS master (>>> 6.9.3 "PROFIBUS mas-
ter/slave EL6731(0010)"
EL6731.0010 PROFIBUS
Page 68)
slave
12 EL6752 DeviceNet master/ (>>> 6.9.4 "DeviceNet mas-
slave ter/slave EL6752(0010)"
Page 69)
13 VARAN slave (>>> 6.9.5 "VARAN slave bus
coupler" Page 69)

Optional Interfaces
Planning
6.8.2 Bus coupler EK1100
Overview
Fig. 6-24: Bus coupler connections
1 Signal output EtherCAT

2 Signal input EtherCAT
3 Power LEDs
4 +24 V supply to bus coupler
5 0 V supply to bus coupler
6 +24 V (+) infeed to power contacts
7 0 V (-) infeed to power contacts
8 PE infeed
Signal Item Description

+24 V 4 +24 V supply to bus coupler
0 V 5 0 V supply to bus coupler
+24 V ext. 1-16 6 +24 V external power supply
for bus coupler reference
point
0 V ext. 1-16 7 0 V external power supply for
bus coupler reference point

6.8.3 Infeed EL9100
Overview
Fig. 6-25: Connections, infeed
1 Infeed 24 V (+) 3 PE infeed

2 Infeed 0 V (-)
6.8.4 16-channel inputs EL1809
Overview
Fig. 6-26: Connections, 16-channel inputs

Optional Interfaces
Planning
Input 1 1 Digital input 1 Reference point 0 V
Input 2 2 Digital input 2 external 1-16
Input 3 3 Digital input 3

6.8.5 16-channel inputs EL1889, negative switching
Overview
Fig. 6-27: Connections, 16-channel inputs


Input 1 1 Digital input 1 Reference point 24 V
Input 2 2 Digital input 2 external 1-16

6.8.6 4-channel 2 A outputs, EL2024
Overview
Fig. 6-28: Connections, 4-channel 2 A outputs
1 Output 1 5 Output 2
2 0 V 6 0 V
3 0 V 7 0 V
4 Output 3 8 Output 4

Optional Interfaces
Planning
6.8.7 2-channel relay outputs EL2622
Overview
Fig. 6-29: Connections, 2-channel relay outputs
1 PE 4 Output 1
2 Power contact N 5 Output 2
3 Power contact L
6.8.8 16-channel outputs EL2809
Overview
Fig. 6-30: Connections, 16-channel 0.5 A outputs


Output 1 1 Digital output 1 0.5 A per output,
Output 2 2 Digital output 2 24 V external
power supply 1-16
Output 3 3 Digital output 3
6.8.9 16-channel outputs EL2889, negative switching
Overview
Fig. 6-31: Connections, 16-channel 0.5 A outputs

Optional Interfaces
Planning
Output 1 1 Digital output 1 0.5 A per output,
Output 2 2 Digital output 2 0 V external pow-
er supply 1-16
6.9 EtherCAT gateways
6.9.1 EtherCAT bridge EL6692
Overview
Fig. 6-32: Connections for EtherCAT bridge EL6692
1 24 V supply
2 EtherCAT Out
3 EtherCAT In

6.9.2 EtherCAT bridge EL6695-1001
Overview
Fig. 6-33: Connections for EtherCAT bridge EL6695
1 24 V supply
2 EtherCAT Out
3 EtherCAT In
EtherCAT bridge EL6695 is only FSoE-capable in the EL6695-1001 var-

iant and can be used as a safe module. This variant is exclusively avail-
able from KUKA Deutschland GmbH.
6.9.3 PROFIBUS master/slave EL6731(0010)
Overview
Fig. 6-34: Connections for PROFIBUS master/slave EL6731
1 Field bus connection

Optional Interfaces
Planning
6.9.4 DeviceNet master/slave EL6752(0010)
Overview
Fig. 6-35: Connections for DeviceNet master/slave EL6752
1 Field bus connection
6.9.5 VARAN slave bus coupler
Overview
Fig. 6-36: Connections for VARAN slave EtherCAT
1 X1 VARAN IN/daisy-chained
2 X3 VARAN OUT
3 X5 EtherCAT IN
4 X6 EtherCAT OUT
5 X4 VARAN OUT
6 X2 VARAN OUT/daisy-chained
7 X7 24 V supply

6.10 Fast Measurement
6.10.1 X33 Fast Measurement inputs (option)
Description
Fast Measurement interface X33 can be used to program search com-

mands in the robot controller for measuring workpieces using digital sen-
sors. Interface X33 is located on the connection panel of the robot control-
ler.
Necessary equipment

• Recommended cable cross-section: 1 mm2
Contact diagram
Pin Description
1 Fast Measurement 1
5 Spare
6 +24V-P
7 GND-Input
8 0V-P
6.10.1.1 Power supply for Fast Measurement
Internal power supply
If the sensors for Fast Measurement are supplied with power by the robot
controller (pin 6 +24V-P, pin 8 GND-P), pin 7 and pin 8 in the customer’s
mating piece for X33 must be connected. In this way, the reference
ground for the Fast Measurement inputs (pin 7 GND-Input) is connected
to the power supply ground of the sensors (pin 8 GND-P).

Optional Interfaces
Planning
Fig. 6-38: Internal power supply for “Fast Measurement”
1 Sensor 1 4 Sensor 4
2 Sensor 2 5 Jumper between GND-INPUT
and 0V-P in connector X33
3 Sensor 3
External power supply
If the sensors for Fast Measurement are supplied externally with power
(not via X33 of the robot controller), the reference ground of the sensors
must be connected to pin 7 GND-Input.
Fig. 6-39: External power supply for “Fast Measurement”
1 Sensor 1 4 Sensor 4
2 Sensor 2 5 0 V external to GND-INPUT
3 Sensor 3 6 24 V DC external
6.11 VARAN interfaces
6.11.1 X67.1 and X67.2 VARAN slave interfaces
Description
Interfaces X67.1 and X67.2 are used to connect the robot controller to a
VARAN bus system.

Necessary equipment
• RJ45 connector

CAT 5e
Pin Description
1 TD+ VARAN IN
2 TD- VARAN IN
3 RD+ VARAN IN
6 RD- VARAN IN
- PE
Pin Description
1 TD+ VARAN OUT
2 TD- VARAN OUT
3 RD+ VARAN OUT
6 RD- VARAN OUT
- PE
6.12 DeviceNet interfaces
6.12.1 DeviceNet interfaces, overview
The following DeviceNet variants are available:

• X14A DeviceNet Master
X14B load voltage US1/US2 X14B

Optional Interfaces
Planning
X14B load voltage US1/US2
X14C DeviceNet Slave In
X14B load voltage US1/US2
X14C DeviceNet Slave In
X14D DeviceNet Slave Out
6.12.1.1 X14A and X14B DeviceNet master

tor" Page 49).
Necessary equipment
Fig. 6-41: Contact diagram, X14A, view from contact side



Pin Description
1 DRAIN
2 24 V
3 0 V
4 CAN_H
5 CAN_L
Pin Description
2 US1 +24 V/5 A
4 US1 0 V
1 US2 +24 V/7 A
3 US2 0 V
6.12.1.2 DeviceNet Slave X14C

tor" Page 49).
Necessary equipment
Fig. 6-43: Contact diagram, X14C, view from contact side

• Recommended connecting cable: DeviceNet cable 2xAWG17,
2xAWG20, drain AWG20

Optional Interfaces
Planning
Connector pin allocation X14C
Pin Description
1 DRAIN
2 24 V
3 0 V
4 CAN_H
5 CAN_L
6.12.1.3 X14C and X14D DeviceNet interface

tor" Page 49).
Necessary equipment
Fig. 6-44: Contact diagram, X14C, view from contact side

Fig. 6-45: Contact diagram, X14D, view from contact side


Connector pin allocation X14C, X14D
Pin Description
1 DRAIN
2 24 V
3 0 V
4 CAN_H
5 CAN_L
6.13 PROFIBUS interfaces
6.13.1 X15A and X15B PROFIBUS interface
Description
Power supply to X15A and X15B can be carried out either directly, from
an external power supply, or by jumpering the internal voltage. If connec-
tor X11 is present, the power supply is switched via X11; if connector X11
is not present, the power supply is switched via connector X55.
The PROFIBUS interface must be configured with Work Visual.
Necessary equipment
• Male connector M23: Bus connector, 17-pole, P-part
• Cable clamping range: Ø9 ... Ø14.7 mm

• Recommended connecting cable: Multibus cable
• Female connector M23: Bus connector, 12-pole, E-part
Fig. 6-47: Contact diagram, X15B, view from contact side

Optional Interfaces
Planning
Connector pin allocation X15A, X15B
Pin Description
1 0 V
4 24 V DC
5 PE
7 PROFI A
8 PROFI B
6.13.2 X61 PROFIBUS master

tor" Page 49).
Necessary equipment

Contact diagram
Pin Description
11 PROFI A
6 PROFI B
5 PE
4 US1 +24 V
1 US1 0 V
3 US2 +24 V

Pin Description
2 US2 0 V
located on the CCU.
6.14 Floating contacts
6.14.1 X31, X32 floating contacts
Description
Interfaces X31 and X32 are floating contacts and are used to connect
customer-specific interfaces.
Necessary equipment
• Female and male connector, M12, A-coded

• Recommended connecting cable: 0.14...0.34 mm2
Fig. 6-49: Contact diagram, view from socket side
Pin Description
1 Contactor US2 output 1
2 Contactor US2 input 1
3 Contactor US2 output 2
4 Contactor US2 input 2
6.15 Cable inlet X51
Description
Four-fold cable inlet for digital inputs/outputs

Optional Interfaces
Planning
Overview
Fig. 6-50: Cable inlet X51
1 Cable inlet clamping range 4.5 ... 10 mm

2 Cable inlet clamping range 9 ... 15 mm
6.16 KLI interfaces
Overview

1 KLI interface X66 (>>> 6.16.1 "X66 Ethernet
interface (RJ45)" Page 79)
2 KLI interface X67 (>>> 6.16.2 "X67.1, X67.2
and X67.3 KLI interfaces"
Page 80)
3 CSP interface (>>> 6.16.3 "KLI interface on
CSP" Page 81)
6.16.1 X66 Ethernet interface (RJ45)
Description
Interface X66 can be used for connecting an external computer to the KU-
KA Line Interface for the purpose of installation, programming, debugging
and diagnosis.
Necessary equipment
• Connector RJ45


CAT 5e
10BASE-T, 100BASE-TX allo-

Pin 1000BASE-TX allocation
cation
1 RX+ BI_DB+
2 RX- BI_DB-
3 TX+ BI_DA+
4 - BI_DD+
5 - BI_DD-
6 TX- BI_DA-
7 - BI_DC+
8 - BI_DC-
6.16.2 X67.1, X67.2 and X67.3 KLI interfaces
Description
The Ethernet interfaces X67.1, X67.2 and X67.3 can be used to connect
the KUKA Line Interface to the system, for example, or to connect a com-
puter to the robot controller.
Necessary equipment
• Connector RJ45

Optional Interfaces
Planning

CAT 5e
Connector pin allocation X67.1, X67.2, X67.3
Pin Description
1 TD+
2 TD-
3 RD+
6 RD-
6.16.3 KLI interface on CSP
Description
The KLI interfaces on the CSP can be used to connect the KUKA Line In-
terface from the switch to the system, for example, or to connect a com-
Necessary equipment
• Connector RJ45


CAT 5e
Connector pin allocation, KLI/KSI
Pin Description
1 TD+
2 TD-
3 RD+
6 RD-
6.16.4 X17A, X17B, X17C KLI interface
Description
The Ethernet interfaces X17A, X17B and X17C can be used to connect
Necessary equipment
• M12 D-coded connector

CAT 5

Optional Interfaces
Planning
Connector pin allocation X17A, X17B, X17C
Pin Description
1 TD+
2 TD-
3 RD+
4 RD-
6.16.5 X17D, X17E, X17F KLI interface
Description
The Ethernet interfaces X17D, X17E and X17F can be used to connect
Necessary equipment

CAT 5
Connector pin allocation X17D, X17E, X17F
Pin Description
1 TD+
2 TD-
3 RD+
4 RD-
6.17 X70 and X71 RoboTeam interface
Description
It is only possible to use the interface if the technology package RoboT-

eam is installed.
Required material X70 and X71

Fig. 6-56: Contact diagram, view from contact side (female)

CAT 5
Connector pin allocation X70 RoboTeam IN
Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
4 TPFI_N
Connector pin allocation X70 RoboTeam OUT
Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
4 TPFI_N
6.17.1 X57 internal power supply
Description
It is only possible to use the interface if the technology package RoboT-

eam is installed. The interface is used for the internal power supply.
Necessary equipment X57
• Connector Han3A
Fig. 6-57: Contact diagram, X57, view from contact side


Optional Interfaces
Planning
Pin Description
1 +24 V PS2 INT
2 GND INT
3 +24 V PS2 external
5 0 V external
The X57 jumpers from pin 1 to pin 3 and pin 2 to pin 5 must be set for
the internal power supply.
The wire jumpers are contained loose in connector bypack X57.
6.18 Euromap interfaces
6.18.1 Overview of E67 interface

1 E67 interface (>>> 6.18.2 "Interface E67"
Page 85)
2 X27 E-STOP and safeguard (>>> 6.18.3 "X27 interface"
Page 87)
3 Cable inlet X51 (>>> 6.15 "Cable inlet X51"
Page 78)
4 X62 PROFIBUS/load voltage (>>> 6.18.4 "X62 Profibus
US1/US2 and load voltage US1/US2
interface" Page 90)
5 X68 Extension Bus (>>> 6.18.5 "X68 interface"
Page 91)
6.18.2 Interface E67
Description
Interface E67 serves as a communication and safety interface for an injec-

tion molding machine.
Necessary equipment
• Screwed connection: M32

• Cable diameter: 14-21 mm
• Recommended cable cross-section: 0.75 mm 2
• Mating connector: Han 25D with a male insert
• Recommended cable cross-section: 0.75 mm 2

• Mating connector: Han 25D with a female insert
Fig. 6-59: Contact diagram, E67, female connector (view from con-
tact side)

ZA1 Test output A Makes the pulsed voltage
ZA3 available for the individual in-
(test signal)
ZA2 Test output B Makes the clocked voltage
ZA4 available for the individual in-
(test signal)
ZA9 +24 V 24 V control voltage for supply
ZC9 to external devices, max. 2 A
0 V
This voltage is available to the
customer
A1/C1 Local E-STOP, channel A Output, floating contacts from
A2/C2 Local E-STOP, channel B internal E-STOP, (>>> "SIB
outputs" Page 29)
In the non-activated state, the
contacts are closed
ZC1 External E-STOP, channel A Dual-channel E-STOP input,
ZC2 External E-STOP, channel B (>>> "SIB inputs" Page 29)
Triggering of the E-STOP func-
tion in the robot controller
A3/C3 Mold area free A36 floating contacts to the
IMM
C5/C6 Safeguard channel A Floating contacts to the IMM,
C7/C8 Safeguard channel B (>>> "SIB outputs" Page 29)
This interface deviates from
the standardized interface E67
ZC3 Safeguard channel A For connection of a dual-chan-
ZC4 Safeguard channel B nel safety gate lock,
(>>> "SIB inputs" Page 29)
As long as the signal is active,
the drives can be switched on.
Only effective in Automatic
modes
ZA5 Reject 24 V input A34 I1
ZA6 Mold closed 24 V input A34 I2
ZA7 Mold open 24 V input A34 I3
ZA8 Intermediate mold opening po- 24 V input A34 I4
sition
ZB2 Fully automatic IMM 24 V input A34 I5

Optional Interfaces
Planning
ZB3 Ejector back position 24 V input A34 I6
ZB4 Ejector forward position 24 V input A34 I7
ZB5 Core pullers free 1 pos. 1 24 V input A34 I8
A6 Enable mold closure 24 V output A38 O1
A7 Enable mold opening 24 V output A38 O2
B2 Operation with HD 24 V output A38 O3
B3 Enable ejector back 24 V output A38 O4
B4 Enable ejector forward 24 V output A38 O5
B5 Core pullers free 1 pos. 1 24 V output A38 O6
A9 + 24 V Power supply, 24 V, external
C9 to IMM
0 V
6.18.3 X27 interface
The X27 safety interface is wired internally to the SIB.
Contact diagram X27
• Mating connector: Han 40D with a male insert

• Screwed connection: M32
• Cable diameter: 14-21 mm
• Recommended cable cross-section: 0.75 mm2


A1 SIB test output A Makes the pulsed voltage
A3 available for the individual in-
(test signal)
A5
These signals may only be
mapped with the SIB.
B1 SIB test output B Makes the clocked voltage
B3 available for the individual in-
(test signal)
B5
These signals may only be
mapped with the SIB.
A4 Safe operational stop, channel Safe operational stop input for
A all axes
B4 Safe operational stop, channel Activation of standstill monitor-
B ing
Stop 0 is initiated if the activa-
ted monitoring is violated.
A6 Safety stop, Stop 2 channel A Safety stop (Stop 2) input for
B6 Safety stop, Stop 2 channel B all axes
Triggering of Stop 2 and acti-
vation of standstill monitoring
at standstill of all axes.
Stop 0 is initiated if the activa-
ted monitoring is violated.
A2 Acknowledge operator safety, For connection of a dual-chan-
channel A nel input for acknowledging
B2 Acknowledge operator safety, operator safety with floating
channel B contacts (>>> "SIB inputs"
Page 29)
The response of the “Operator
safety acknowledgement” input
can be configured in the
KUKA system software.
After closing the safety gate
(operator safety), manipulator
motion can be enabled in the
automatic modes using an ac-
knowledge button outside the
safety fence. This function is
deactivated on delivery.
A7 Peri enabled channel A Output, floating contact
A8 (>>> "SIB outputs" Page 29)
B7 Peri enabled channel B (>>> "Signal “Peri enabled”

(PE)" Page 89)
B8
C1 Output, channel 1 (K 20) Output, test signal, channel
D1 Output, channel 2 (K 20) 1/2 for C2/D2

Optional Interfaces
Planning
C2 Input E-STOP, channel 1 Connection for EMERGENCY
(K 20) STOP button on the robot
D2 Input E-STOP, channel 2 safety enclosure
(K 20) Signal affects robot and IMM
C3 Output, channel 1 (K 21) Output, test signal, channel
D3 Output, channel 2 (K 21) 1/2 for C4/D4
C4 Input, safeguard channel 1 Connection for door switch for

(K 21) the robot safety enclosure
D4 Input, safeguard channel 2 The signal only affects the ro-
(K 21) bot.
For IMMs, the E73 interface of
the IMM must be configured
with a separate door switch.
Operator safety acknowledgement
The SIB input signal “Operator safety acknowledgement” (from the IMM) is
switched via E67 and also via interface X27. The E67 standard does not
include an additional acknowledging signal for the operator safety ac-
knowledgement input signal. The following configuration of interface X27
is therefore required:
• The following configurations of interface X27 with a safety gate switch
are possible:
‒ QBS signal is not switched
‒ Gate switch with integrated acknowledge button for providing a
qualified operator safety signal
‒ Configuration of the operator safety acknowledgement as “external
module” in the safety configuration
• The following configurations of interface X27 with a safety PLC are
possible:
‒ Switching of the QBS signal by the PLC
‒ Switching of the operator safety signal by the PLC
‒ Configuration of QBS as “by acknowledgement button” in the safe-
ty configuration
Signal “Peri enabled” (PE)
The signal “Peri enabled” is set to 1 (active) if the following conditions are
met:
• Drives are switched on.
• Safety controller motion enable signal present.
• The message “Operator safety open” must not be active.
This message is not active in the modes T1 and T2.
“Peri enabled” in conjunction with the signal “Safe operational stop”
• In the case of activation of the signal “Safe operational stop” during
the motion:
‒ Error -> braking with Stop 0. “Peri enabled” eliminated.
• Activation of the signal “Safe operational stop” with the manipulator
stationary:
Release the brakes, switch drives to servo-control and monitor for re-
start. “Peri enabled” remains active.

‒ Signal “Motion enable” remains active.

‒ US2 voltage (if present) remains active.
‒ Signal “Peri enabled” remains active.
“Peri enabled” in conjunction with the signal “Safety stop 2”
• In the case of activation of the signal “Safety stop 2”:
‒ Stop 2 of the manipulator.
‒ Signal “Drive enable” remains active.
‒ Brakes remain released.
‒ Manipulator remains under servo-control.
‒ Monitoring for restart active.
‒ Signal “Motion enable” is deactivated.
‒ US2 voltage (if present) is deactivated.
‒ Signal “Peri enabled” is deactivated.
6.18.4 X62 Profibus and load voltage US1/US2 interface
Description
The load voltages are not switched, so that the valve terminal on the arm
of the manipulator is always energized.
Necessary equipment

Pin Description
11 PROFI A
6 PROFI B
5 PE

Optional Interfaces
Planning
Pin Description
4 US1 +24 V/ 5 A
1 US1 0 V
3 U21 +24 V/ 7 A
2 U21 0 V
6.18.5 X68 interface
US1 0 V
Pin Description
1 TPFO_P
2 TPFO_N
3 TPFI_P
6 TPFI_N
6.19 Performance level
The safety functions of the robot controller conform to Category 3 and

Performance Level d according to EN ISO 13849-1.
6.19.1 PFH values of the safety functions
The safety values are based on a service life of 20 years.

The PFH value classification of the controller is only valid if the EMER-
GENCY STOP device and the enabling switches on the smartPAD are
tested at least once every 12 months.
When evaluating system safety functions, it must be remembered that the
PFH values for a combination of multiple controllers may have to be taken
into consideration more than once. This is the case for RoboTeam sys-
tems or higher-level hazard areas. The PFH value determined for the
safety function at system level must not exceed the limit for PL d.
The PFH values relate to the specific safety functions of the different con-
troller variants.
Safety function groups:
• Standard safety functions

‒ Operating mode selection
‒ Operator safety
‒ EMERGENCY STOP device
‒ Enabling device
‒ External safe operational stop
‒ External safety stop 1
‒ External safety stop 2
‒ Velocity monitoring in T1
‒ Control of the peripheral contactor
• Safety functions of KUKA Safe Operation Technology (optional)
‒ Monitoring of axis spaces

‒ Monitoring of Cartesian spaces

‒ Monitoring of axis velocity
‒ Monitoring of Cartesian velocity
‒ Monitoring of axis acceleration
‒ Safe operational stop
‒ Tool monitoring
Overview of controller variant PFH values:
Robot controller variant PFH value
KR C4; KR C4 CK < 1 x 10-7
KR C4 midsize; KR C4 midsize CK < 1 x 10-7
KR C4 extended; KR C4 extended CK < 1 x 10-7
KR C4 NA; KR C4 CK NA < 1 x 10-7
KR C4 NA variant: TTE1 < 1 x 10-7
KR C4 NA extended; KR C4 CK NA extended < 1 x 10-7
KR C4 variant: TBM1 < 1 x 10-7
KR C4 variants: TDA1; TDA2; TDA3; TDA4 < 1 x 10-7
KR C4 smallsize-2 variants: TDA4 < 1 x 10-7
KR C4 variants: TFO1; TFO2 < 2 x 10-7
KR C4 variants: TRE1; TRE2 < 1.8 x 10-7
KR C4 variant: TRE3 < 1 x 10-7
KR C4 variants: TVO1; TVO2; TVO3 < 1 x 10-7
VKR C4 variants: TVW1; TVW2; TVW3; TVW4, TVW5, < 1 x 10-7
TVW6, TVW7, TVW8
VKR C4 smallsize-2 variants: TVW1; TVW3, TVW7, < 1 x 10-7
TVW8
VKR C4 Retrofit KR C1 < 2.7 x 10-7
VKR C4 Retrofit KR C2 < 1 x 10-7
KR C4 Panel Mounted < 1 x 10-7
KR C4 compact < 1 x 10-7
KR C4 compact slimline < 1 x 10-7
KR C4 smallsize < 1 x 10-7
KR C4 smallsize-2 < 1 x 10-7
KR C4 smallsize-2 with KR C4 smallsize drive box < 1 x 10-7
For controller variants that are not listed here, please contact KUKA
Deutschland GmbH.

Optional Interfaces
Maintenance
7 Maintenance
7.1 Safety Interface Board Extended
The maintenance work, tests and test cycles for the SIB Extended are
specified in the operating instructions of the KR C4 robot controller.

Maintenance Optional Interfaces

Optional Interfaces
KUKA Service
8 KUKA Service
8.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.
Information
The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used
8.2 KUKA Customer Support
Availability
KUKA Customer Support is available in many countries. Please do not

hesitate to contact us if you have any questions.
Argentina
Ruben Costantini S.A. (Agentur)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

KUKA Service Optional Interfaces
Australia
KUKA Robotics Australia Pty Ltd
45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
info@kuka-robotics.com.au
www.kuka-robotics.com.au
Belgium
KUKA Automatisering + Robots N.V.
Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil
KUKA Roboter do Brasil Ltda.
Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
info@kuka-roboter.com.br
www.kuka-roboter.com.br
Chile
Robotec S.A. (Agency)
Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China
KUKA Robotics China Co., Ltd.
No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
info@kuka-robotics.cn
www.kuka-robotics.com

Optional Interfaces
KUKA Service
Germany
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
Hotline.robotics.de@kuka.com
www.kuka.com
France
KUKA Automatisme + Robotique SAS
Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr
India
KUKA India Pvt. Ltd.
Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
info@kuka.in
www.kuka.in
Italy
KUKA Roboter Italia S.p.A.
Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

Japan
KUKA Japan K.K.
YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
info@kuka.co.jp
Canada
KUKA Robotics Canada Ltd.
2865 Argentia Road, Unit 4-5
Mississauga
Ontario L5N 8G6
Canada
Tel. +1 905 858‑5852
Fax +1 905 858-8581
KUKAFocusCenter@KUKARobotics.com
www.kukarobotics.ca
Korea
KUKA Robotics Korea Co. Ltd.
RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com
Malaysia
KUKA Robot Automation (M) Sdn Bhd
South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
info@kuka.com.my

Optional Interfaces
KUKA Service
Mexico
KUKA de México S. de R.L. de C.V.
Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
www.kuka-robotics.com/mexico
Norway
KUKA Sveiseanlegg + Roboter
Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
info@kuka.no
Austria
KUKA CEE GmbH
Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 732 784 752 0
Fax +43 732 793 880
KUKAAustriaOffice@kuka.com
www.kuka.at
Poland
KUKA CEE GmbH Poland
Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka.com
Portugal
KUKA Robots IBÉRICA, S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
info.portugal@kukapt.com
www.kuka.com

Russia
KUKA Russia OOO
1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
support.robotics.ru@kuka.com
Sweden
KUKA Svetsanläggningar + Robotar AB
A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland
KUKA Roboter CEE GmbH
Linz, Zweigniederlassung Schweiz
Heinrich Wehrli-Strasse 27
5033 Buchs
Switzerland
Tel. +41 62 837 43 20
info@kuka-roboter.ch
Slovakia
KUKA CEE GmbH
organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
support.robotics.cz@kuka.com
Spain
KUKA Iberia, S.A.U.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
comercial@kukarob.es

Optional Interfaces
KUKA Service
South Africa
Jendamark Automation LTD (Agentur)
76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Taiwan
KUKA Automation Taiwan Co. Ltd.
1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
info@kuka.com.tw
Thailand
KUKA (Thailand) Co. Ltd.
No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
HelpdeskTH@kuka.com
Czech Republic
KUKA Roboter CEE GmbH
organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
support.robotics.cz@kuka.com
Hungary
KUKA HUNGÁRIA Kft.
Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

USA
KUKA Robotics Corporation
51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
CustomerService@kuka.com
www.kuka.com
United Kingdom
KUKA Robotics UK Ltd
Great Western Street
Wednesbury West Midlands
WS10 7LL
United Kingdom
Tel. +44 121 505 9970
Fax +44 121 505 6589
service@kuka-robotics.co.uk
www.kuka-robotics.co.uk

Optional Interfaces
Index Documentation, industrial robot....................... 7

Dual NIC........................................................... 8
27V PWR NA US1/US2 X14B.......................52
Dynamic testing.............................................. 41
27V PWR US1/US2 X14B............................. 50
“Drives ready” lamp, X53...............................43
2-channel relay outputs..................................65
24 V external power supply...........................27 E
24V PWR IN NA X14A.................................. 55 E67 EtherCAT modules..................................25
27V PWR IN NA X14A.................................. 54 E67 interface.................................................. 85
27V PWR IN X14A........................................ 55 E67 switching devices....................................25
27V PWR US1 X54....................................... 49 E67 upper side connection panel..................21
EA................................................................... 10
EDS...................................................................8
A EDS cool...........................................................8
Assignment of slot 14.................................... 21 EL1809............................................................62
Assignment of slot 15.................................... 22 EL1889............................................................63
Assignment of slot 2...................................... 15 EL2024............................................................64
EL6695............................................................68
EL6731(0010)................................................. 68
EL6752 (0010)................................................69
B EL9100............................................................62
BR M.................................................................8 EMC.................................................................. 8
Bus coupler EK1100.......................................61 EMD.................................................................. 8
Bus coupler, overview.................................... 60 Enabling switches, external............................43
EtherCAT bridge.......................................67, 68
External power supply...............................46
C X67.1..........................................................59
Cable inlet X51...............................................78 X67.2..........................................................59
CCU.................................................................. 8 EtherCAT interfaces....................................... 58
CIB.................................................................... 8 EtherCAT, gateways....................................... 67
CIP Safety........................................................ 8 Ethernet
CK..................................................................... 8 Interfaces................................................... 56
Connector pin allocation X27.........................88 Ethernet interface
Connector pin allocation X42.........................43 X66 (RJ45)................................................ 79
Connector X27................................................87 Ethernet/IP........................................................ 8
Connector X62................................................90 Euromap interfaces........................................ 85
Connector X68................................................91 External axis enabling switch
Contact diagram X27..................................... 87 Function..................................................... 44
CSP...................................................................8 External power supply....................................45
EtherCAT bridge........................................ 46
Switch........................................................ 46
D VARAN slave............................................. 46
Data cables.....................................................13 X55.............................................................46
DeviceNet interfaces...................................... 72 External power supply X33............................71
DeviceNet master........................................... 73 External power supply, X11........................... 45
DeviceNet master/slave..................................69 External voltage..............................................30
DeviceNet Slave............................................. 74
DeviceNet Slave IN and OUT....................... 75
DeviceNet X14A............................................. 73 F
DeviceNet X14B............................................. 73 Fast Measurement
DeviceNet X14C.......................................74, 75 Interfaces................................................... 70
DeviceNet X14D............................................. 75 Floating contacts............................................ 78
DeviceNet, interfaces..................................... 72
Digital I/O interface 32/32/4........................... 24
Digital I/O modules 16/16.............................. 22 G
Digital I/O modules 16/16/4........................... 23 Gateways, EtherCAT...................................... 67
Digital I/O modules, overview........................ 60

Optional Interfaces
H Load voltages................................................. 47
HMI................................................................... 8 Low-voltage power supply unit................26, 46
Technical data........................................... 30
Lower connection panel................................. 14
I
Infeed................................................. 13, 54, 62
Inputs, 16-channel................................... 62, 63
M
Inputs, Fast Measurement............................. 70 Maintenance................................................... 93
Intended use................................................... 11 Maintenance, SIB Extended ......................... 93
Interface Manipulator....................................................... 9
X64.1..........................................................57 Motor cables................................................... 13
X64.2..........................................................57
X64.3..........................................................57
Interface E67.................................................. 85 N
Interface X70.................................................. 83 NA..................................................................... 9
Interface X71.................................................. 83
Interface, E67................................................. 85
Interface, EtherCAT X65................................ 58 O
Interfaces, DeviceNet..................................... 72 Outputs, 16-channel.................................65, 66
Interfaces, discrete......................................... 34 Outputs, 4-channel, 2 A outputs....................64
Interfaces, overview........................................13 Overview, E67................................................ 85
Introduction....................................................... 7 Overview, robot controller.............................. 13
K P
KCB...................................................................8 PE cables....................................................... 13
KEB...................................................................8 PELV................................................................. 9
KLI.....................................................................8 PELV power supply unit.................................30
KLI interface on CSP..................................... 81 Performance level...........................................91
KLI interfaces........................................... 22, 79 Peripheral cables............................................13
KONI................................................................. 8 PFH values..................................................... 91
KPC...................................................................8 PL....................................................................91
KPP...................................................................8 Planning.......................................................... 33
KR C4............................................................. 13 PLC................................................................... 9
KR C4 extended.............................................13 PoE................................................................... 9
KR C4 extended CK...................................... 13 Power cable....................................................13
KR C4 midsize............................................... 13 Power supply
KR C4 midsize CK.........................................13 Fast Measurement.................................... 70
KR C4 CK.......................................................13 Internal....................................................... 70
KRL................................................................... 9 Power supply, external................................... 45
KSB...................................................................9 X14B.......................................................... 53
KSI.................................................................... 9 X14B2........................................................ 53
KSI interfaces................................................. 22 Product description.........................................13
KSP...................................................................9 PROFIBUS interface X15A............................ 76
KSS...................................................................9 PROFIBUS interface X15B............................ 76
KUKA Customer Support............................... 95 PROFIBUS master X61................................. 77
KUKA Service.................................................95 PROFIBUS master/slave................................68
KUKA smartPAD cable...................................13 Profibus X62................................................... 90
PROFIBUS, interfaces....................................76
PROFINET SYNC, X63..................................56
L Purpose...........................................................11
Load voltage contactor
Checking.................................................... 49
Load voltage US1...........................................49 Q
X56.............................................................48 QBS.................................................................. 9
Load voltage US1/US2...................................90
X11.............................................................47
Load voltage US2 R
X56.............................................................48
RDC.................................................................. 9

Optional Interfaces
RDC cool.......................................................... 9 V
Reference switch, X42................................... 43 VARAN slave
RoboTeam interface....................................... 83 External power supply...............................46
RTS...................................................................9 VARAN slave bus coupler..............................69
VARAN, interfaces..........................................71
S
Safe Operation Technology............................34 W
Safely isolated................................................ 30 Warnings........................................................... 7
SafeOperation X13......................................... 35
SafeOperation, X13........................................ 34
SafeOperation, X42........................................ 43
SafeRangeMonitoring, X13............................ 37 X
SafeSingleBrake, X13.................................... 39 X11
Safety..............................................................31 Load voltage US1/US2............................. 47
Safety instructions............................................ 7 X11, external power supply............................45
Safety Interface Board................................... 27 X13, SafeOperation........................................ 34
Safety Interface Board Extended...................29 X13, SafeRangeMonitoring............................ 37
Safety options, interface.................................34 X13, SafeSingleBrake.................................... 39
Safety options, interfaces...............................34 X14A 24V PWR IN NA.................................. 55
SATA connections............................................ 9 X14A 27V PWR IN........................................ 55
SG FC...............................................................9 X14A 27V PWR IN NA.................................. 54
SIB..............................................................9, 27 X14A, connector pin allocation................55, 56
SIB description............................................... 27 X14B
SIB Extended..................................................29 24V PWR NA US1/US2............................52
SIB functions.................................................. 27 27V PWR US1.......................................... 51
SIB inputs....................................................... 29 Power supply, external..............................53
SIB outputs..................................................... 29 X14B 27V PWR NA US1/US2.......................52
SIB, safe input................................................41 X14B 27V PWR US1/US2............................. 50
SIB, safe output..............................................42 X14B connector pin allocation................. 51–53
Signal “Peri enabled”......................................89 X14B2
SION................................................................. 9 Power supply, external..............................53
SOP.................................................................. 9 X17, KLI interfaces.................................. 82, 83
SRM.................................................................. 9 X31, X32 floating contacts.............................78
SSB...................................................................9 X31, X32 interface..........................................78
Support request.............................................. 95 X33
Switch External power supply...............................71
External power supply...............................46 Inputs, Fast Measurement........................ 70
Switch overview..............................................22 Internal power supply................................70
X53, “Drives ready” lamp...............................43
X55
External power supply...............................46
T X56
Target group....................................................11 Load voltage US1/US2............................. 48
Technical data.................................................29 X57
Terms used....................................................... 8 Interface..................................................... 84
Test output A..................35, 37, 39, 44, 86, 88 X61
Test output B..................35, 37, 39, 44, 86, 88 PROFIBUS master.................................... 77
Trademarks....................................................... 8 X63, PROFINET SYNC..................................56
Training........................................................... 11 X64.1
Interface..................................................... 57
X64.2
U Interface..................................................... 57
US1................................................................... 9 X64.3
US2................................................................. 10 Interface..................................................... 57
US2 function X65..................................................................58
Checking.................................................... 49 X66
USB.................................................................10 Ethernet interface (RJ45)..........................79
X67, KLI interfaces.........................................80
X67.1...............................................................59

Optional Interfaces
X67.1, VARAN................................................ 71
X67.2...............................................................59
X67.2, VARAN................................................ 71

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Book structure: MA KR C4 Interfaces V11.1

Version: MA KR C4 Interfaces V13

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6.4.2 X56 load voltages US1/US2................................................................................. 48

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6.15 Cable inlet X51...................................................................................................... 78

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1.1 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.2 Representation of warnings and notes

These warnings contain references to safety-relevant information or gen-

This warning draws attention to procedures which serve to prevent or rem-

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

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• Windows is a trademark of Microsoft Corporation.

• EtherCAT® is a registered trademark and patented tech-

• CIP Safety® is a trademark of ODVA.

1.4 Terms used

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2.1 Target group

This documentation is aimed at users with the following knowledge and

• Advanced knowledge of electrical and electronic systems

For optimal use of our products, we recommend that our customers

2.2 Intended use

The following interfaces are options for the KR C4 robot controllers:

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Any use or application deviating from the intended use is deemed to be

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3.1 Overview of the KR C4 robot controller

The optional interfaces are for the following KR C4 robot controllers:

Fig. 3-1: Overview of robot controllers

3.2 Optional interfaces, connection panel

The connection panel of the robot controller consists of connections for

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3.3 Lower connection panel

Fig. 3-2: Lower connection panel

1 Slot 1 (>>> "Assignment of slot 1" Page 14)

Slot 1 can be assigned the following interfaces:

X70 RoboTeam input -

X70 RoboTeam input -

X53 “Drives ready” lamp -

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X70 RoboTeam input -

• 27V PWR US1/US2

X70 RoboTeam input -

Slot 2 can be assigned the following interfaces:

X51 Wieland four-way cable -

X56 Load voltages X56 can be selected

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Slot Connector Description Comment

X54 27 V PWR US1 X54 can be selected

X56 Load voltages X56 can be selected

X14A 4-pole X14A can be selec-

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Slot 3 can be assigned the following interfaces: