CONTROL CABINET

KR C2

Operating Handbook

Connection / Periphery

Issued: 01 Jul 2004 Version: 00

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

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

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

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

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 Operating Handbook

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 1 Connection panel overview

1 Connection panel overview

The installation shall be made by qualified personal and should conform to all
national and local codes!

All the connectors on the connector panel are plug--and--socket connections as

defined by VDE 0627.
Accordingly, these plug--and--socket connections must not be plugged or
unplugged while the controller is operational (i.e. energized).
Before these plug--and--socket connections are plugged or unplugged, the
controller and the cables concerned must be deenergized.
KUKA Control Panel

Connection panel
KR C2 control cabinet

1 2 3 4 5 6 7 8 9
10
11

Control Panel

Connection panel, robot

Motor cable

Data cable

X30/X30.2 X31
PE1
PE2

Fig. 1 Cable connections

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

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

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 Operating Handbook

2 Connector pin allocation

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

2.1 Power supply connection

Caution: connecting cable with toroidal cores

Q1 Toroidal cores

Q1/1 L1 Incoming supply only with

transformer:
Q1/3 L2 3 x 380 V 50/60 Hz xx A
3 x 400 V 50/69 Hz xx A
Q1/5 L3 3 x 440 V 50/60 Hz xx A
3 x 480 V 50/60 Hz xx A
XQ1 3 x 575 V 50/60 Hz xx A

PE Fusing min. 3x25 A

PE max. 3x32 A

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 2 Connector pin allocation (Fortsetzung)

2.2 Peripheral connector X11

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

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

9 4 External E--STOP channel A

10 22 External E--STOP channel B
Safety module ESC board

X10
1 6 Enabling channel A
2 24 Enabling channel B

3 8 Safeguard channel A
4 26 Safeguard channel B

12 41 Test output A
11 42 Drives OFF external

10 43 Test output B
9 44
Drives ON external

5 50 Qualifying input A
6 51
Qualifying input B

X12 Optional

1 90 24 V DC control voltage, 6 A
2 36
24 V DC control voltage, 4 A
3 72
0 V control voltage
4 18
0 V control voltage

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 Operating Handbook

Peripheral interface X11 (continued)

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

8 2
Local E--STOP channel B
9 3
Local E--STOP channel B
1 20
Local E--STOP channel A
0
11 21
Local E--STOP channel A
Safety module ESC board

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

9 12
Drives ON channel A
1 11
Drives ON channel A
0

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

7 106
+24 V internal, 4 A
8 107 0 V internal

More detailed information on the X11 interface can be found under 2.7.

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 2 Connector pin allocation (Fortsetzung)

2.3 KCP connector X19

KVGA X19

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

SHIELD

SHIELD

A1.2

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

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 Operating Handbook

2.4 Motor connector X20, axes 1 to 6

X20
X2
4 a1
Motor A1--U1
N1 3 a2
Motor A1--V1
2 a3
Motor A1--W1
X2
4 b1
Motor A2--U1
N2 3 b2
Motor A2--V1
2 b3
Motor A2--W1
X2
4 c1
Motor A3--U1
N3 3 c2
Motor A3--V1
2 c3
Motor A3--W1
X2
4 d1
Motor A4--U1
N4 3 d4
Motor A4--V1
2 d6
Motor A4--W1

X2
4 e1
Motor A5--U1
N5 3 e4
Motor A5--V1
2 e6
Motor A5--W1
X2
4 f1
Motor A6--U1
N6 3 f4
Motor A6--V1
2 f6
Motor A6--W1

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

PE
Ground conductor 6.0 mm2

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 2 Connector pin allocation (Fortsetzung)

2.5 Optional motor connector X7

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

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

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

F14.2
a1

Connector monitoring
G1 X114 --7
a2

PE
Ground

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 Operating Handbook

2.6 Data cable connector X21, axes 1 to 8

X21

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

A32

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

5
DR
13 OG 9
/DR
9 BK 10
/FSX
1 YE 11
FSX
10 BK 12
/DX
2 GN 13
DX
14 BK 14
/CLKR
6
BU 15
CLKR

16
NC
17
NC

Housing

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 2 Connector pin allocation (Fortsetzung)

2.7 Interface signals X11

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

causes immediate disconnection of the drives!

Interface signal Pin Description Remarks

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

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 Operating Handbook

Interface signal Pin Description Remarks

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

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

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 2 Connector pin allocation (Fortsetzung)

2.8 EMERGENCY STOP circuits

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

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

X11

0 V internal 107

89

24 V internal 106

88

Local E--STOP channel A 2

Local E--STOP channel A 3

Local E--STOP channel B 20

Local E--STOP channel B 21

Test output A 1

External E--STOP channel A 4

ESC
Test output B 19

External E--STOP channel B 22

E--STOP circuit for one robot without periphery and

without external ESC power supply

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 Operating Handbook

X11
0 V internal 107

89

24 V internal 106

88

Local E--STOP channel A 2

Local E--STOP channel A 3

Local E--STOP channel B 20 PLC

Local E--STOP channel B 21

Test output A 1

External E--STOP channel A 4

ESC 19
Test output B

External E--STOP channel B 22

External
E--STOP
in the
periphery
Emergency Stop circuit for one robot with
periphery
X11
0 V internal 107

89 0V
external
24 V internal 106

88 24 V
external

Local E--STOP channel A 2

Local E--STOP channel A 3

Local E--STOP channel B PLC
20

Local E--STOP channel B 21

Test output A 1

External E--STOP channel A 4

ESC
Test output B 19

External E--STOP channel B 22

External
E--STOP
in the
Emergency Stop circuit for one robot with periphery periphery
and external power supply

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 2 Connector pin allocation (Fortsetzung)

Control voltage, external

X11
107 0V

72
0V 24 V
16
Control voltage
106 4A 24 V
L-- 90 6A
L+
36 4A
21 Local E--STOP channel B
S21
20 Local E--STOP channel B
Y3
Emergency Stop switching device (e.g. PNOZ 10)

3 Local E--STOP channel A

S11
2 Local E--STOP channel A

Safeguard 26 Safeguard channel B

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

E--STOP enabling switch 6 Enabling channel A

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

OFF 42 Drives OFF external

Drives

43

33 39 24 V test output B

25 24 V test output B

23 24 V test output B

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

7 24 V test output A

5 24 V test output A

1 24 V test output A
13

44 34 88 24 V external VCC

Power supply for 89 0 V external GND

safety circuit
22 4 1 19 89 88 20 2 21 3

X11 -- robot 2

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

peripheral connector X11

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 Operating Handbook

2.9 Safety gate monitor

L+ A1 (+) Safety gate monitor

Ue e.g. PST3, manuf.: Pilz

L --- A2 ( ---)

= safety gate open

S11
= safety gate closed

= actuated element
S12

Gate position switches S23

S24

X1

Pushbutton for enable

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

7 8 25 26
Peripheral connector X11
Safeguard channel A

Safeguard channel B
Test output B
Test output A

KR C2

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

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 2 Connector pin allocation (Fortsetzung)

2.10 Service jumper plug for X11 -- KR C2

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

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

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

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

38
Test output A
39
Test output B

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

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

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 Index

C
Connecting cables, 5
Connection panel, 5
Connector pin allocation, 6

D
Data cable connector X21, 12

E
EMERGENCY STOP circuits, 15
Equipotential bonding, 5

G
Ground conductor, 5

I
Interface signals X11, 13

K
KCP connector X19, 9
KUKA Control Panel, 5

M
Motor connector X20, 10
Motor connector X7, 11

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

S
Safety gate monitor, 18
Service jumper plug X11, 19

T
Toroidal cores, 6

X
X11, 7, 8

Index -- i