ROBOT

(V)KR 6; (V)KR 16; (V)KR 6 K; (V)KR 16 K

Description

Electrical Installations

Issued: 01 Dec 2004 Version: 02

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

PD Interleaf

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Contents

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

2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Cabling plans and pin allocation diagrams . . . . . . . . . . . . . . . . . . . . . . . . 10

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Description

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 1 General

Valid for (V)KR 6 KR 6 K

(V)KR 16, ...CR KR 16 K
(V)KR 16 L6 KR 16 L6 K

1 General
The electrical installations of the robot form a separate assembly. It includes the “cable set”
(Fig. 1), containing all electric cables (Fig. 2 to Fig. 3). The cable set has plug--and--socket
connections so that exchanges can be quickly carried out. This dispenses with the need for
wiring work.
The arrangement, designation and allocation of the cables may be noted from the various
diagrams. The connectors are provided with identification labels. The ground conductors are
fastened with cable lugs to threaded bolts.

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Description

2 Description
Installed on the base frame are two junction boxes (Fig. 1/6, 7). The motor cables for axes
1 to 6 are grouped together in junction box X01 (7) and are wired up to a rectangular
flange--mounted connector. This connector is at the same time the connector on the robot
for the connecting cable (“motor cable”) between the robot and the control cabinet. The
connector consists of six separate connector modules. Each connector module is assigned
a particular motor connector (e.g. XM1). The ground conductors are connected to a ground
conductor rail (Fig. 14) in the junction box (Fig. 1/7).
The control cables for axes 1 to 6 are grouped together in junction box X02 (6) and are
connected to an RDC board. Each control cable has a separate connector and can therefore
be exchanged individually. The interface at the junction box (6) with the connecting cable
(“data cable”) between the robot and the control cabinet is formed by a 17--pole right--angle
connector.
At the back of the junction boxes (6, 7) are cable glands. From these glands, the cables are
routed to the base frame and from there via a common flexible tube A 1 (5) to the rotating
column. The flexible tube A 1 ensures a low--stress routing of the supply lines as well as
reducing the number of mechanical interface contours, without impairing the rotational
motion of axis 1. The cables for the drive units of axes 1 and 2 branch off in the rotating
column.
The cables for the motor units of axes 3 to 6 run from the rotating column to the arm in a
flexible tube (4) inside the hollow link arm. The flexible tubes (4, 5) prevent the cables from
kinking.
The cables installed in the robot are summarized in tabular form in Fig. 2 and Fig. 4 and are
shown schematically in Fig. 5.

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 2 Description (continued)

XP4 XM4
XP5
1 XM5
XP6 2
XM6
XP3--L
XM3

XM2
XP2
XP1
XM1

5
6
7

X30

X31

1 Connectors for control cables

2 Connectors for motor cables
3 Ground conductor
4 Flexible tube A 2/A 3 from rotating column to arm
5 Flexible tube A 1 from base frame to rotating column
6 Junction box X02 for control cables
7 Junction box X01 for motor cables

Fig. 1 Cable set assembly

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Description

Cable from to Cable from to

Ground conductor Bolt on Bolt on Control cable A 1 Connector X1 XP1
00--116--223 base frame rotating column 00--116--214
Bolt on Bolt on Control cable A 2 Connector X2 XP2
rotating column arm 00--116--215
Motor cable A 1 Connector X30 XM1 Control cable A 3 Connector X3 XP3--L
00--116--208 00--125--181
Motor cable A 2 Connector X30 XM2 Control cable A 4 Connector X4 XP4
00--116--209 00--116--217
Motor cable A 3 Connector X30 XM3 Control cable A 5 Connector X5 XP5
00--116--210 00--116--218
Motor cable A 4 Connector X30 XM4 Control cable A 6 Connector X6 XP6
00--116--211 00--116--219
Motor cable A 5 Connector X30 XM5 Connecting cable Connector X9 X31
00--116--212 00--107--132
Motor cable A 6 Connector X30 XM6 Mastering cable Connector X10 X32
00--116--213 00--106--299

Fig. 2 Table of cables installed (standard)

XM5 XP5

NOTE: The exact arrangement of

junction boxes X01 and X02 is shown
XM6 XP6
in Fig. 1.
XP3--L XM3

XM4 XP4

Board

X31
X6
X32
XP2 XM2 X5
X4 X10
X3 X9
X2
XM1 XP1 X1
X02

Modules
a to f

X31 a
b
X32 c
d
e
X30 f

X01

Fig. 3 Electrical installations (block diagram)

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 2 Description (continued)

Cable from to Cable from to

Ground conductor Bolt on Bolt on Control cable A 1 Connector X1 XP1
00--119--694 base frame rotating column 00--119--724
Bolt on Bolt on Control cable A 2 Connector X2 XP2
rotating column arm 00--119--725
Motor cable A 1 Connector X30 XM1 Control cable A 3 Connector X3 XP3--L
00--119--701 00--125--182
Motor cable A 2 Connector X30 XM2 Control cable A 4 Connector X4 XP4
00--119--705 00--119--727
Motor cable A 3 Connector X30 XM3 Control cable A 5 Connector X5 XP5
00--119--708 00--119--729
Motor cable A 4 Connector X30 XM4 Control cable A 6 Connector X6 XP6
00--119--709 00--119--730
Motor cable A 5 Connector X30 XM5 Connecting cable Connector X9 X31
00--119--720 00--107--132
Motor cable A 6 Connector X30 XM6 Mastering cable Connector X10 X32
00--119--721 00--106--299

Fig. 4 Table of cables installed (shelf--mounted robot)

XM5 XP5

NOTE: The exact arrangement of

junction boxes X01 and X02 is shown
XM6 XP6
in Fig. 1.
XP3--L XM3

XM4 XP4

Board

X31
X6
X32
XP2 XM2 X5
X4 X10
X3 X9
X2
XM1 XP1 X1
X02

Modules
a to f

X31 a
b
X32 c
d
e
X30 f

X01

Fig. 5 Electrical installations (block diagram)

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Description

3 Cabling plans and pin allocation diagrams

Connector X30, Pin no. Assignment Connector X31, Pin no. Assignment

1 module in each case

a1 A 1/motor U 1 24 V lamp
2 GND
3 24V
a2 A 1/motor V 4 A1/CLKO
5 A1/CLKO
a3 A1/motor W 6 FSi
b1 A 2/motor U 7 /FSi
8 Di
9 /Di
b2 A 2/motor V 10 /FSo
11 FSo
b3 A 2/motor W 12 /Do
c1 A 3/motor U 13 Do
14 /CLKi
15 CLKi
c2 A 3/motor V 16 not connected
17 0 V lamp
c3 A 3/motor W
d1 A 4/motor U
d2 not connected
d3 Brake + A 1/A 4
d4 A4/motor V
d5 Brake -- A 1/A 4
d6 A4/motor W
e1 A5/motor U
e2 not connected
e3 Brake + A 2/A 5
e4 A5/motor V
e5 Brake -- A 2/A 5
e6 A 5/motor W
f1 A 6/motor U
f2 not connected
f3 Brake + A3/A6
f4 A6/motor V
f5 Brake -- A3/A6
f6 A6/motor W
PE Ground conductor
PE Ground conductor

Fig. 6 Connector pin allocation X30 Fig. 7 Connector pin allocation X31

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 3 Cabling plans and pin allocation diagrams (continued)

Motor Brake Motor Resolver

temp.

M + --
W S1 S3 S2 S4 R1 R2
U V

XM1 1 2 6 4 5 8 9 11 12 1 2 10 7
XP1
Connector
housing

Housing
X01 Housing
X02
X30a 1 2 3 X30d 3 5 2 1 9 8 3 7 6 5 4
X1

Rail

Fig. 8 Cabling plan, drive A 1

Motor Brake Motor Resolver

temp.

M + --
W S1 S3 S2 S4 R1 R2
U V

XM2 1 2 6 4 5 8 9 11 12 1 2 10 7
XP2
Connector
housing

Housing
X01 Housing
X02
X30b 1 2 3 X30e 3 5 2 1 9 8 3 7 6 5 4
X2

Rail

Fig. 9 Cabling plan, drive A 2

Motor Brake Motor Resolver

temp. Option
KIR function
M + --
24 V

S1 S3 S2 S4 R1 R2
0V

W
U V

XM3 1 2 6 4 5 8 9 11 12 1 2 10 7 3 4
XP3
Connector
housing

Housing
Housing
X01
X02
X30c 1 2 3 X30f 3 5 2 1 9 8 3 7 6 5 4 1 17
X3 X31

Rail

Fig. 10 Cabling plan, drive A 3

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Description

Motor Brake Motor Resolver

temp.

M + --
W S1 S3 S2 S4 R1 R2
U V

XM4 1 2 6 4 5 8 9 11 12 1 2 10 7
XP4
Connector
housing

Housing XM1
X01 4 5

Housing
X02
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30d X4

Rail

Fig. 11 Cabling plan, drive A 4

Motor Brake Motor Resolver

temp.

M + --
W S1 S3 S2 S4 R1 R2
U V

XM5 1 2 6 4 5 8 9 11 12 1 2 10 7
XP5

Housing XM2
X01 4 5

Housing
X02
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30e X5

Rail

Fig. 12 Cabling plan, drive A 5

Motor Brake Motor Resolver

temp.

M + --
W S1 S3 S2 S4 R1 R2
U V

XM6 1 2 6 4 5 8 9 11 12 1 2 10 7
XP6

Housing XM3
X01 4 5

Housing
X02
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30f X6

Rail

Fig. 13 Cabling plan, drive A 6

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 3 Cabling plans and pin allocation diagrams (continued)

Arm Bolt

Bolt

Rotating column

Junction box X02 from junction

XM1/
XM2/
XM3/
XM4/
XM5/
XM6/
for control cables box X02 for
control cables
Bolt

Base frame

Junction box X01

for motor cables

X30

Fig. 14 Ground conductor installation

XP3--L/3 XP3--L/4
X9
Coding pin

14 15 10 11 7 6 9 8 3 2 5 4 13 12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
X31

Fig. 15 Cabling plan, RDC board connecting cable

Signal A0

Signal A1
24 V

0V

X10
3 4 2 1

2 1 6 5
X32

Fig. 16 Cabling plan, mastering

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