Controller Option KUKA Roboter GmbH

KUKA Interface X12 with 16 I/Os

Functional Description

Issued: 05.05.2009

Version: KUKA KR C2 X12 / 16 I/O DeviceNet-Modul V6 en

 KUKA Interface X12 with 16 I/Os

© Copyright 2009
KUKA Roboter GmbH
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 the KUKA Roboter 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 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, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original operating instructions
KIM-PS5-DOC

Publication: Pub KUKA KR C2 X12 / 16 I/O DeviceNet-Modul en

Book structure: KUKA KR C2 X12 / 16 I/O DeviceNet-Modul V1.7
Label: KUKA KR C2 X12 / 16 I/O DeviceNet-Modul V6

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 Contents

Contents
1 Introduction .................................................................................................. 5
1.1 Target group .............................................................................................................. 5

2 Product description ..................................................................................... 7

2.1 Scope of supply ......................................................................................................... 7
2.2 Overview of the robot controller ................................................................................. 7
2.3 Description ................................................................................................................. 8
2.3.1 Connection assignment X12 / CAN I/O module .................................................... 9
2.3.2 CAN I/O module power supply ............................................................................. 11

3 Safety ............................................................................................................ 13
3.1 Representation of warnings and notes ...................................................................... 13
3.2 Safety instructions ...................................................................................................... 13
3.3 Designated use .......................................................................................................... 13

4 Installation ................................................................................................... 15
4.1 Installation .................................................................................................................. 15

5 Configuration ............................................................................................... 17
5.1 Configuring the file IOSYS.INI ................................................................................... 17

6 KUKA Service .............................................................................................. 19

6.1 Requesting support .................................................................................................... 19
6.2 KUKA Customer Support ........................................................................................... 19

Index ............................................................................................................. 25

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 1. Introduction

1 Introduction

1.1 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 system
„ 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 pro-
gram can be found at www.kuka.com or can be obtained directly from our
subsidiaries.

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 2. Product description

2 Product description

2.1 Scope of supply

The following components are supplied for installation:

„ Connector X12 / 108 contacts
„ CAN I/O module with 50-contact connector
„ Interface cable (W108275) for the connection between X12 and the CAN
I/O module
„ 5-pole cable (W108276) for power supply to the CAN I/O module

2.2 Overview of the robot controller

The following systems are operated with the robot controller:

„ KUKA robots
„ KUKA Motion Control
„ External kinematics
The robot controller consists of the following components:
„ Control PC
„ Power unit
„ KCP teach pendant
„ Safety logic ESC
„ KCP coupler (optional)
„ Service socket (optional)
„ Connection panel

Fig. 2-1: Overview of the robot controller

1 Power unit 6 Safety logic (ESC)

2 Control PC 7 KCP coupler card (optional)
KCP coupler, control and Connection panel
3 8
indicator elements (optional)

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 KUKA Interface X12 with 16 I/Os

4 KCP 9 Service socket (optional)

Mounting plate for customer Main switch
5 10
components

2.3 Description

The interface X12 with integrated CAN I/O module for 16 I/Os is an optional
connection to the robot controller which offers:
„ 16 digital inputs (freely programmable), consisting of 2 groups of 8 inputs
(IEC 1131-2 type). Each group has its own ground connection.
„ 16 digital low-current outputs (freely programmable) of max. 500 mA each,
consisting of 2 groups of 8 outputs. Each group has its own error signature
and an external 24 V power supply.
„ 4 digital high-current outputs (freely programmable) with max. 2 A each
and an external power supply. The group has its own ground connection.
All inputs and outputs are insulated from one another and from the bus.
Each input and output has its own status LED.
The outputs are protected against overvoltage, short-circuit and overtempera-
ture.
Mac ID and baud rate settings are made via rotary switches or DIP switches
(address 0 to 63) (>>> Fig. 2-2). Structure and setting mode are manufactur-
er-specific.

Fig. 2-2: Setting the Mac ID address

Each device must have an address that exists only once in the bus system.

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 2. Product description

2.3.1 Connection assignment X12 / CAN I/O module

Fig. 2-3: Connection assignment X12 / CAN I/O module

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 KUKA Interface X12 with 16 I/Os

Assignment of
Signal Description
X12
57 +24V Power supply for outputs of group 0
75 0V GND for outputs of group 0
93 OUT 1 Output 1, group 0, Imax= 0.5 A
58 OUT 2 Output 2, group 0, Imax= 0.5 A
76 OUT 3 Output 3, group 0, Imax= 0.5 A
94 OUT 4 Output 4, group 0, Imax= 0.5 A
59 OUT 5 Output 5, group 0, Imax= 0.5 A
77 OUT 6 Output 6, group 0, Imax= 0.5 A
95 OUT 7 Output 7, group 0, Imax= 0.5 A
60 OUT 8 Output 8, group 0, Imax= 0.5 A
78 +24V Power supply for outputs of group 1
96 0V GND for outputs of group 1
61 OUT 9 Output 9, group 1, Imax= 0.5 A
79 OUT 10 Output 10, group 1, Imax= 0.5 A
97 OUT 11 Output 11, group 1, Imax= 0.5 A
62 OUT 12 Output 12, group 1, Imax= 0.5 A
80 OUT 13 Output 13, group 1, Imax= 0.5 A
98 OUT 14 Output 14, group 1, Imax= 0.5 A
63 OUT 15 Output 15, group 1, Imax= 0.5 A
81 OUT 16 Output 16, group 1, Imax= 0.5 A
55 +24V Power supply for outputs of group 2
73 0V GND for outputs of group 2
91 OUT 17 Output 17, group 2, Imax= 2 A
56 OUT 18 Output 18, group 2, Imax= 2 A
74 OUT 19 Output 19, group 2, Imax= 2 A
92 OUT 20 Output 20, group 2, Imax= 2 A
99 0V Zero potential for inputs of group 0
64 IN 1 Input 1, group 0
82 IN 2 Input 2, group 0
100 IN 3 Input 3, group 0
65 IN 4 Input 4, group 0
83 IN 5 Input 5, group 0
101 IN 6 Input 6, group 0
66 IN 7 Input 7, group 0
84 IN 8 Input 8, group 0
102 0V Zero potential for inputs of group 0
67 IN 9 Input 9, group 1
85 IN 10 Input 10, group 1
103 IN 11 Input 11, group 1
68 IN 12 Input 12, group 1
86 IN 13 Input 13, group 1
104 IN 14 Input 14, group 1
69 IN 15 Input 15, group 1
87 IN 16 Input 16, group 1

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 2. Product description

2.3.2 CAN I/O module power supply

The CAN I/O module is supplied with power by the ESC-CI plug-in card. This
is connected by means of the 5-contact cable W108276.

Fig. 2-4: CAN I/O module power supply

CAN I/O module, assignment

Signal Description
of X1
5 +24 V Power supply
4 CAN + CAN High signal
3 Drain Shielding
2 CAN - CAN Low signal
1 GND Ground connection

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 3. Safety

3 Safety

3.1 Representation of warnings and notes

Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.

Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.

Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.

Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.

Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.

Tips to make your work easier or references to further information.

3.2 Safety instructions

User The user must meet the following preconditions:

„ The user must have read and understood the robot system documenta-
tion, including the safety chapter.
„ The user must be trained for the work to be carried out.
„ Work on the robot system must only be carried out by qualified personnel.
These are people who, due to their specialist training, knowledge and ex-
perience, and their familiarization with the relevant standards, are able to
assess the work to be carried out and detect any potential dangers.

3.3 Designated use

Use The option “X12 / 16 I/O DeviceNet Module” is a digital interface between the
KR C2 robot controller and an external device.

Misuse Any use or application deviating from the designated use is deemed to be im-
permissible misuse. The manufacturer cannot be held liable for any damage
resulting from such use. The risk lies entirely with the user.
Examples of misuse include:
„ Operation outside the permissible operating parameters
„ Plugging and unplugging connectors when energized
Caution!
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.

No liability can be accepted if these directions are disregarded.

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 4. Installation

4 Installation

4.1 Installation

Precondition „ All persons working with the robot system must have read and understood
the robot system documentation, including the safety chapter.
„ The option “X12 interface 16 I/Os” must be installed and operated in ac-
cordance with the applicable national laws, regulations and standards.
Danger!
Before installation or removal work is started, it must be ensured that the
main switch is in the OFF position and that measures have been taken to
prevent it from being inadvertently energized again.

Before installing and connecting the option “X12 interface 16 I/Os”, please re-
fer to the accompanying circuit diagram and cabling description.

Procedure 1. Open the cabinet door and remove the blanking plate of the X12 interface
slot.
2. Install the X12 connector.
3. Fasten the CAN I/O module to the top-hat rail.
4. Connect X12 and the CAN I/O module with interface cable W108275.
5. Connect the CAN I/O module and the ESC-CI board with cable W108276.

Fig. 4-1: Installation position for X12 with DeviceNet I/O module with 16
I/Os

1 Top-hat rail
2 Installation position for X12
3 CAN I/O module
4 ESC-CI board

The installation position of X12 may vary from that illustrated above.

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 5. Configuration

5 Configuration

5.1 Configuring the file IOSYS.INI

The file IOSYS.INI is the configuration file of the I/O system.

Precondition „ All communications cables have been installed.

„ User group “Expert”
„ The driver file mfcdrv.o must be available in the directory C:\Krc\Robot-
er\Drivers.

Procedure 1. Select the menu sequence Configure > I/O Driver > Edit I/O Config..
The file IOSYS.INI is opened.
2. In [DRIVERS]: Activate the driver MFC=0,mfcEntry,mfcdrv.0.
3. In [MFC]: Assign input and output addresses.
4. Select the menu sequence Configure > I/O Driver > Reconfigure I/O
Driver.
The settings are saved.

The menu item Reset restarts the bus. Changes are not saved.

Description
1 [CONFIG]
2 VERSION=2.00

3 [DRIVERS]
4 MFC=0,mfcEntry,mfcdrv.0

5 [MFC]
6 INW2=0
7 OUTW4=0
8 OUTW2=2

Line Description
1 [CONFIG] section
2 Indication of the version number
3 [DRIVERS] section
4 Activation of the bus driver
5 [MFC] section
6 ... 8 Configuring the inputs/outputs

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 6. KUKA Service

6 KUKA Service

6.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.

Faults leading to production downtime should be reported to the local KUKA

subsidiary within one hour of their occurrence.

Information The following information is required for processing a support request:

„ Model and serial number of the robot
„ Model and serial number of the controller
„ Model and serial number of the linear unit (if applicable)
„ Version of the KUKA System Software
„ Optional software or modifications
„ Archive of the software
„ Application used
„ Any external axes used
„ Description of the problem, duration and frequency of the fault

6.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

Australia Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au

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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.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@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 Flexible Manufacturing Equipment (Shanghai) Co., Ltd.

Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de

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 6. KUKA Service

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 Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
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 Robotics Japan K.K.

Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
info@kuka.co.jp

Korea KUKA Robot Automation Korea Co. Ltd.

4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com

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Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my

Mexico KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx

Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no

Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at

Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt

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 6. KUKA Service

Russia OOO KUKA Robotics Rus

Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru

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 Schweiz AG

Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

Spain KUKA Sistemas de Automatización S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 814-2353
Fax +34 93 814-2950
Comercial@kuka-e.com
www.kuka-e.com

South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

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Taiwan KUKA Robot Automation Taiwan Co. Ltd.

136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de

Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com

UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk

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 Index

Index
C
Configuration 17
Configuration, IOSYS.INI 17
Connection assignment X12 / CAN I/O module 9
Connection panel 7
Control PC 7

D
Designated use 13

I
Installation 15
Installation position 15
Introduction 5
IOSYS.INI, configuration 17

K
KUKA Customer Support 19

O
Overview of the robot controller 7

P
Power unit 7
Product description 7

R
Robot controller 7

S
Safety 13
Safety instructions 13
Safety logic 7
Scope of supply 7
Service, KUKA Roboter 19
Setting the Mac ID address 8
Support request 19

T
Target group 5
Teach pendant 7
Training 5

U
User 13

W
Warnings 13

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