Controller Option KUKA Roboter GmbH

Optional Interfaces

For KR C4 Robot Controllers

Assembly and Operating Instructions

Optional Inter-

faces

Issued: 24.10.2016

Version: MA KR C4 Interfaces V10

 Optional Interfaces

© Copyright 2016
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 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 documentation
KIM-PS5-DOC

Publication: Pub MA KR C4 Interfaces (PDF) en

Book structure: MA KR C4 Interfaces V9.1
Version: MA KR C4 Interfaces V10

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 Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Trademarks ................................................................................................................ 7
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 ............................................................... 20
3.5 KLI/KSI interfaces ..................................................................................................... 21
3.6 Digital I/O modules and bus coupler .......................................................................... 21
3.6.1 Digital I/O modules 16/16 ..................................................................................... 21
3.6.2 Digital I/O modules 16/16/4 .................................................................................. 22
3.6.3 Digital I/O interface 32/32/4 .................................................................................. 23
3.6.4 EtherCAT modules and switching devices, E67 interface .................................... 24
3.7 Safety Interface Board ............................................................................................... 25
3.8 24 V external power supply ........................................................................................ 26

4 Technical data .............................................................................................. 27

4.1 External 24 V power supply ....................................................................................... 27
4.2 Safety Interface Board Extended ............................................................................... 27

5 Safety ............................................................................................................ 29
6 Planning ....................................................................................................... 31
6.1 Discrete interfaces for safety options ......................................................................... 32
6.1.1 SafeRobot interface X13 ....................................................................................... 32
6.1.1.1 X13 SafeOperation interface ........................................................................... 33
6.1.1.2 X13 SafeRangeMonitoring interface ................................................................ 35
6.1.1.3 X13 SafeSingleBrake interface ........................................................................ 36
6.1.1.4 Wiring examples for safe inputs and outputs ................................................... 38
6.1.2 X53 “Drives ready” lamp ....................................................................................... 40
6.1.3 X42 reference switch ............................................................................................ 40
6.1.4 X58 external enabling switches ............................................................................ 41
6.2 External power supplies ............................................................................................. 42
6.2.1 X11 external power supply ................................................................................... 42
6.2.2 X55 external power supply ................................................................................... 42
6.3 Load voltages ............................................................................................................ 43
6.3.1 X11 load voltages US1 and US2 .......................................................................... 43
6.3.2 X56 load voltages US1/US2 ................................................................................. 44
6.3.3 X54 interface 27V PWR US1 ................................................................................ 45
6.3.4 Checking the US2 function, load voltage contactor .............................................. 46
6.3.5 X14B interface 27V PWR US1/US2 ..................................................................... 46

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6.3.6 X14B interface 27V PWR US1 ............................................................................. 47

6.3.7 X14B interface 27V PWR NA US1/US2 ............................................................... 47
6.3.8 X14B interface 24V PWR NA US1/US2 ............................................................... 48
6.4 Infeed ......................................................................................................................... 49
6.4.1 X14A interface 27V PWR IN NA ........................................................................... 49
6.4.2 X14A interface 27V PWR IN ................................................................................. 49
6.4.3 X14A interface 24V PWR IN NA ........................................................................... 50
6.5 Ethernet interfaces .................................................................................................... 50
6.5.1 X63 PROFINET SYNC interface .......................................................................... 50
6.5.2 KONI interface X64.1, X64.2 and X64.3 ............................................................... 51
6.6 EtherCAT interfaces .................................................................................................. 52
6.6.1 X65 EtherCAT interface ........................................................................................ 52
6.6.2 X67.1 and X67.2 EtherCAT bridge interfaces ...................................................... 53
6.7 EtherCAT input/output modules ................................................................................ 53
6.7.1 Digital I/O modules and bus coupler ..................................................................... 54
6.7.2 Bus coupler EK1100 ............................................................................................. 55
6.7.3 Infeed EL9100 ...................................................................................................... 56
6.7.4 16-channel inputs EL1809 .................................................................................... 56
6.7.5 16-channel inputs EL1889, negative switching .................................................... 57
6.7.6 4-channel 2 A outputs, EL2024 ............................................................................ 58
6.7.7 2-channel relay outputs EL2622 ........................................................................... 59
6.7.8 16-channel outputs EL2809 ................................................................................. 59
6.7.9 16-channel outputs EL2889, negative switching .................................................. 60
6.8 EtherCAT gateways ................................................................................................... 61
6.8.1 EtherCAT bridge EL6692 ..................................................................................... 61
6.8.2 EtherCAT bridge EL6695-1001 ............................................................................ 62
6.8.3 PROFIBUS master/slave EL6731(0010) .............................................................. 62
6.8.4 DeviceNet master/slave EL6752(0010) ................................................................ 63
6.8.5 VARAN slave bus coupler .................................................................................... 63
6.9 Fast Measurement ..................................................................................................... 63
6.9.1 X33 Fast Measurement inputs (option) ................................................................ 63
6.9.1.1 Power supply for Fast Measurement ............................................................... 64
6.10 Euromap interfaces ................................................................................................... 65
6.10.1 X67.1 and X67.2 VARAN slave interfaces ........................................................... 65
6.11 DeviceNet interfaces ................................................................................................. 66
6.11.1 DeviceNet interfaces, overview ............................................................................ 66
6.11.1.1 X14A and X14B DeviceNet Master ................................................................. 66
6.11.1.2 DeviceNet Slave X14C .................................................................................... 67
6.11.1.3 X14C and X14D DeviceNet interface .............................................................. 68
6.12 PROFIBUS interfaces ................................................................................................ 69
6.12.1 X15A and X15B PROFIBUS interface .................................................................. 69
6.12.2 X61 PROFIBUS master ........................................................................................ 70
6.13 Floating contacts ....................................................................................................... 71
6.13.1 X31, X32 floating contacts .................................................................................... 71
6.14 Cable inlet X51 .......................................................................................................... 72
6.15 KLI interfaces ............................................................................................................. 72
6.15.1 X66 Ethernet interface (RJ45) .............................................................................. 72
6.15.2 X67.1, X67.2 and X67.3 KLI interfaces ................................................................ 73
6.15.3 KLI interface on CSP ............................................................................................ 73

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6.15.4 X17A, X17B, X17C KLI interface .......................................................................... 74

6.15.5 X17D, X17E, X17F KLI interface .......................................................................... 75
6.16 X70 and X71 RoboTeam interface ............................................................................. 75
6.16.1 X57 interface, internal power supply ..................................................................... 76
6.17 Interface E67 ............................................................................................................. 76
6.17.1 Interface E67 ........................................................................................................ 77
6.17.2 X27 interface ......................................................................................................... 78
6.17.3 X62 load voltage US1/US2 ................................................................................... 81
6.17.4 X68 interface ......................................................................................................... 82
6.18 Performance level ...................................................................................................... 82
6.18.1 PFH values of the safety functions ....................................................................... 82

7 Maintenance ................................................................................................. 85
7.1 Safety Interface Board Extended ............................................................................... 85

8 KUKA Service .............................................................................................. 87

8.1 Requesting support .................................................................................................... 87
8.2 KUKA Customer Support ........................................................................................... 87

Index ............................................................................................................. 95

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 1 Introduction

1 Introduction
t

1.1 Industrial robot documentation

t

The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.2 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

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.

1.3 Trademarks

 Windows is a trademark of Microsoft Corporation.

 EtherCAT® is a registered trademark and patented technol-

ogy, licensed by Beckhoff Automation GmbH, Germany.

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 Optional Interfaces

 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
extended 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
KRL KUKA Robot Language
KUKA programming language
KSB KUKA System Bus
A field bus for internal networking of the control-
lers

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 1 Introduction

Term Description
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
installations
M{Number} Motor {Number}
NA North America
PELV Protective Extra Low Voltage
External 24 V power supply
QBS Operator safety acknowledgment signal
RDC Resolver Digital Converter (KR C4)
RDC cool Resolver Digital Converter (KR C4) with
extended 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
SPS (PLC) A Programmable Logic Controller
is used in systems as a higher-level master mod-
ule 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
US2 Load voltage (24 V) switched. Deactivates actu-
ators, for example, when the drives are deacti-
vated
USB Universal Serial Bus
Bus system for connecting additional devices to
a computer
EA External axis (linear unit, Posiflex)

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 2 Purpose

2 Purpose
2

2.1 Target group

s

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 ob-
tained directly 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
 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
 X70 and X71 RoboTeam input and output
 X57 power supply
The following interfaces are options for the KR C4 midsize robot controller:
 E67 Euromap interface
 X27 E-STOP and safeguard connection
 X51 Wieland four-way cable inlet
 X62 PROFIBUS master

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 Optional Interfaces

 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 imper-
missible misuse. This includes e.g.:
 Operation outside the permissible operating parameters
 Use in potentially explosive environments

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 3 Product description

3 Product description

3.1
t
Overview of the KR C4 robot controller
s

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 fol-
lowing 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 customer-
specific version and the options required.

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 Optional Interfaces

3.3 Lower connection panel

Overview

Fig. 3-2: Lower connection panel

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

2 Slot 2 (>>> "Assignment of slot 2" Page 15)
3 Slot 3 (>>> "Assignment of slot 3" Page 17)
4 Slot 4 (>>> "Assignment of slot 4" Page 17)
5 Slot 5 (>>> "Assignment of slot 5" Page 19)
6 Slot 6 (>>> "Assignment of slot 6" Page 19)

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

Assignment of Slot 1 can be assigned the following interfaces:

slot 1
Slot Connector Description Comment
X51 Wieland four-way cable -
inlet for digital inputs/out-
puts

X70 RoboTeam input -

X71 RoboTeam output
X57 Infeed, PS2 external -

X70 RoboTeam input -

X71 RoboTeam output
X53 “Drives ready” lamp -

X53 “Drives ready” lamp -

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 3 Product description

Slot Connector Description Comment

X70 RoboTeam input -
X71 RoboTeam output
X54 27V PWR US1 X54 can be selected
individually

X70 RoboTeam input -

X71 RoboTeam output
X14B 4-pole X14B can be
selected individually
 27V PWR NA
US1/US2
 24V PWR NA
US1/US2
5-pole
 27V PWR US1/US2
 27V PWR US1
X70 RoboTeam input -
X71 RoboTeam output
X58 External enabling switch X58 can be selected
individually

Assignment of Slot 2 can be assigned the following interfaces:

slot 2
Slot Connector Description Comment
X13 Safe digital inputs and -
outputs for SafeRobot

X51 Wieland four-way cable -

inlet for digital inputs/out-
puts

X56 Load voltages X56 can be selected

individually
X33 Fast measurement X33 can be selected
individually

X53 “Drives ready” lamp X53 can be selected

individually
X33 Fast measurement X33 can be selected
individually

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 Optional Interfaces

Slot Connector Description Comment

X54 27V PWR US1 X54 can be selected
individually
X33 Fast measurement X33 can be selected
individually

X56 Load voltages X56 can be selected

individually
X58 External enabling switch X58 can be selected
individually

X14A 4-pole X14A can be

selected individually
 27V PWR IN NA
5-pole
 27V PWR IN
X14B 4-pole X14B can be
selected individually
 24V PWR NA
US1/US2
 24V PWR NA
US1/US2
5-pole
 27V PWR US1/US2
 27V PWR US1
X58 External enabling switch X58 can be selected
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
4-pole
together
 24V PWR IN
X14B Load voltage
4-pole
 24V PWR IN NA
US1/US2
X14A External 24 V supply X14A and X14B
must be selected
4-pole
together
 24V PWR IN NA
US1/US2
X14B Load voltage
4-pole
 24V PWR IN NA
US1/US2
X58 External enabling switch X58 can be selected
individually

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 3 Product description

Assignment of Slot 3 can be assigned the following interfaces:

slot 3
Slot Connector Description Comment
X11  Digital safety -
 Ext. power supplies
 Load voltages
 EMERGENCY STOP
devices on the robot
controller
X56 Load voltages X56 can be selected
individually
X55 External power supplies X55 can be selected
individually

X51 Wieland four-way cable -

inlet for digital inputs/out-
puts

X17A KUKA Line Interface via M12 D-coded

switch
X17B KUKA Line Interface via
switch
X17C KUKA Line Interface via
switch

Assignment of Slot 4 can be assigned the following interfaces:

slot 4
Slot Connector Description Comment
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
X67.2 KUKA Line Interface via RJ 45
switch
X67.3 KUKA Line Interface via RJ 45
switch
X65 KUKA Extension Bus X65 can be selected
individually
X66 KUKA Line Interface X66 can be selected
individually

X61 PROFIBUS master X61 can be selected

individually
X66 KUKA Line Interface X66 can be selected
individually

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 Optional Interfaces

Slot Connector Description Comment

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

X14A DeviceNet master -

X14B Load voltages -
X66 KUKA Line Interface X66 can be selected
individually

X33 Fast measurement X33 can be selected

individually
X66 KUKA Line Interface X66 can be selected
individually

X51 Wieland four-way cable -

inlet for digital inputs/out-
puts

X33 Fast measurement X33 can be selected

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)
X65 KUKA Extension Bus X65 can be selected
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

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 3 Product description

Assignment of Slot 5 can be assigned the following interfaces:

slot 5
Slot Connector Description Comment
X33 Fast measurement X33 can be selected
individually
X65 KUKA Extension Bus X65 can be selected
individually

X33 Fast measurement X33 can be selected

individually
X66 KUKA Line Interface X66 can be selected
individually

X14C DeviceNet slave IN -

X14D DeviceNet slave OUT -
X33 Fast measurement -

X64.1 KONI via switch -

X64.2 KONI via switch -
X64.3 KONI via switch -

X67.1 KUKA Line Interface via RJ 45

switch
X67.2 KUKA Line Interface via RJ 45
switch
X67.3 KUKA Line Interface via RJ 45
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

Assignment of Slot 6 is assigned the following interfaces:

slot 6

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Slot Connector Description Comments

X21.1 RDC2 connection KR C4 extended only
X19 smartPAD connection -
X21 RDC1 connection -
X42 Mastering probe for Saf- X42 can be selected
eRobot optionally.

3.4 E67 interface, upper side connection panel

Overview

Fig. 3-3: E67 connection panel

1 Blanking plate
2 Slot 12 (>>> "Assignment of slot 12" Page 20)
3 Slot 13 (>>> "Assignment of slot 13" Page 20)
4 Slot 14 (>>> "Assignment of slot 14" Page 20)
5 Slot 15 (>>> "Assignment of slot 15" Page 21)

Assignment of Slot 12 is assigned the following interface:

slot 12
Slot Connector Description Comments
X51 Wieland four-fold cable -
inlet for digital inputs/out-
puts

Assignment of Slot 13 is assigned the following interfaces:

slot 13
Slot Connector Description Comments
X68 KUKA Extension Bus X68 can be selected
individually.
X62 PROFIBUS master X62 can be selected
individually.

Assignment of Slot 14 can be assigned the following interfaces:

slot 14

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 3 Product description

Slot Connector Description Comments

X27 EMERGENCY STOP and -
safeguards

Assignment of Slot 15 can be assigned the following interfaces:

slot 15
Slot Connector Description Comments
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 are 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 con-
figured, 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:

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 Optional Interfaces

 EtherCAT bus coupler

 EtherCAT 16x input terminal
 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
modules 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 bus coupler
 EtherCAT 16x input terminal
 EtherCAT 16x output terminal
 EtherCAT infeed terminal
 EtherCAT 4x output terminal
 EtherCAT bus end cap

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 3 Product description

Fig. 3-6: Digital module 16/16/4

1 KEI connection X1
2 EK1100 bus coupler A20
3 EL1809/ EL1889 input terminal A21
4 EL2809/ EL2889 output terminal A22
5 EL9100 infeed terminal A23
6 EL2024 output terminal A27
7 EL9011 bus end cap

Detailed information about the EtherCAT bus coupler and the I/O
modules can be found in the manual from Beckhoff.

3.6.3 Digital I/O interface 32/32/4

Overview The digital I/O interface 32/32/4 consists of the following components:
 EtherCAT bus coupler
 EtherCAT 16x input terminal
 EtherCAT 16x output terminal
 EtherCAT infeed terminal
 EtherCAT 4x output terminal
 EtherCAT bus end cap

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Fig. 3-7: Digital modules 32/32/4

1 KEI connection X1
2 EK1100 EtherCAT bus coupler A20
3 EL1809/ EL1889 input terminal A21
4 EL2809/ EL2889 output terminal A22
5 EL9100 infeed terminal A23
6 EL1809/ EL1889 input terminal A24
7 EL2809/ EL2889 output terminal A25
8 EL9100 infeed terminal A26
9 EL2024 output terminal A27
10 EL9011 bus end cap

Detailed information about the EtherCAT bus coupler and the I/O
modules can be found in the manual from Beckhoff.

3.6.4 EtherCAT modules and switching devices, E67 interface

Overview The digital I/O interface for the E67 interface consists of the following compo-
nents:
 EtherCAT bus coupler
 PROFIBUS master
 PROFIBUS slave
 EtherCAT 16x input terminal
 EtherCAT 16x output terminal
 EtherCAT infeed terminal
 EtherCAT 4x output terminal
 EtherCAT 2x relay output terminal
 EtherCAT bus end cap

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 3 Product description

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
4 EL9100 infeed terminal A33
5 EL1809 input terminal A34
6 EL9100 infeed terminal A35
7 EL2622 relay output terminal A36
8 EL9100 infeed terminal A37
9 EL2809 output terminal A38
10 EL9011 bus end cap
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

Detailed information about the EtherCAT bus coupler and the I/O
modules can be found in the manual from Beckhoff.

Fuse rating
Item Fuse Value Designation
11 F41 2A External power supply

3.7 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 Ex-
tended SIB, depending on the configuration of the safety interface. The Stan-
dard 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:

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 Safe inputs and outputs for the discrete safety interface of the robot con-
troller
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

3.8 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
The external power supply to the SIB and CIB boards cannot be isolated. If the
SIB is supplied externally, the CIB is also supplied externally, and vice versa.

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 4 Technical data

4 Technical data
4

4.1 External 24 V power supply

PELV external
t External voltage PELV power supply unit acc. to EN
power supply 60950 with rated voltage 27 V (18 V
... 30 V), safely isolated
Continuous current >8A
Cable cross-section of power sup- ≥ 1 mm2
ply cable
Cable length of power supply cable < 50 m, or < 100 m wire length (out-
going 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.

4.2 Safety Interface Board Extended

SIB outputs
The power contacts must only be fed from a safely isolated PELV
power supply unit. (>>> 4.1 "External 24 V power supply" Page 27)

Operating voltage, power contacts ≤ 30 V

Current via power contact min. 10 mA
< 750 mA
Cable lengths (connection of actua- < 50 m cable lengths
tors)
< 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 ex-
ceeded.

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SIB inputs Switching level of the inputs The state for the inputs is not
defined for the voltage range from
5 V to 11 V (transition range). Either
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 (out-
going 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

Test outputs A and B are sustained short-circuit proof.

The specified currents flow via the contact element connected to the
input. This must be rated for the maximum current of 15 mA.

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 5 Safety

5 Safety
f

y This documentation contains safety instructions which refer specifically to the

product described here. The fundamental safety information for the industrial
robot can be found in the “Safety” chapter of the operating or assembly instruc-
tions for the robot controller.

The “Safety” chapter in the operating instructions or as-

sembly instructions of the robot controller must be ob-
served. Death to persons, severe injuries or considerable damage to
property may otherwise result.

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 6 Planning

6 Planning
Overview Step Description Information
1 Load voltage US1 and US2 (>>> 6.3.1 "X11 load volt-
interface X11 ages US1 and US2"
Page 43)
2 External power supply via (>>> 6.2.1 "X11 external
interface X11 power supply" Page 42)
3 Check US2 function of load (>>> 6.3.4 "Checking the
voltage contactors US2 function, load voltage
contactor" Page 46)
4 SafeRobot interface X13 (>>> 6.1.1 "SafeRobot inter-
face X13" Page 32)
5 DeviceNet interface X14A (>>> 6.11.1 "DeviceNet
interfaces, overview"
Page 66)
6 27V PWR IN NA interface (>>> 6.4.1 "X14A interface
X14A 27V PWR IN NA" Page 49)
7 27V PWR IN interface X14A (>>> 6.4.2 "X14A interface
27V PWR IN" Page 49)
8 27V PWR US1/US2 interface (>>> 6.3.5 "X14B interface
X14B 27V PWR US1/US2"
Page 46)
9 27V PWR US1 interface (>>> 6.3.6 "X14B interface
X14B 27V PWR US1" Page 47)
10 27V PWR NA US1/US2 inter- (>>> 6.3.7 "X14B interface
face X14B 27V PWR NA US1/US2"
Page 47)
11 24V PWR NA US1/US2 inter- (>>> 6.3.8 "X14B interface
face X14B 24V PWR NA US1/US2"
Page 48)
12 PROFIBUS interface X15A (>>> 6.12.1 "X15A and
and X15B X15B PROFIBUS interface"
Page 69)
13 Fast Measurement interface (>>> 6.9.1 "X33 Fast Mea-
X33 surement inputs (option)"
Page 63)
14 Mastering probe SafeRobot (>>> 6.1.3 "X42 reference
interface X42 switch" Page 40)
15 Cable inlet interface X51 (>>> 6.14 "Cable inlet X51"
Page 72)
16 “Drives ready” lamp inter- (>>> 6.1.2 "X53 “Drives
face X53 ready” lamp" Page 40)
17 27V PWR US1 interface X54 (>>> 6.3.3 "X54 interface
27V PWR US1" Page 45)
18 External power supply inter- (>>> 6.2.2 "X55 external
face X55 power supply" Page 42)
19 Load voltage US1 and US2 (>>> 6.3.2 "X56 load volt-
interface X56 ages US1/US2" Page 44)
20 External enabling interface (>>> 6.1.4 "X58 external
X58 enabling switches" Page 41)
21 PROFIBUS master interface (>>> 6.12.2 "X61 PROFI-
X61 BUS master" Page 70)

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Step Description Information

22 PROFINET SYNC interface (>>> 6.5.1 "X63 PROFINET
X63 SYNC interface" Page 50)
23 KONI interfaces X64.1, (>>> 6.5.2 "KONI interface
X64.2 and X64.3 X64.1, X64.2 and X64.3"
Page 51)
24 KUKA Extension Bus inter- (>>> 6.6.1 "X65 EtherCAT
face X65 interface" Page 52)
25 VARAN slave EtherCAT (>>> 6.10.1 "X67.1 and
X67.2 VARAN slave inter-
faces" Page 65)
26 EtherCAT bridge (mas- (>>> 6.6.2 "X67.1 and X67.2
ter/master) EtherCAT bridge interfaces"
Page 53)
27 KLI interfaces (>>> 6.15 "KLI interfaces"
Page 72)
28 RoboTeam interface X70 and (>>> 6.16 "X70 and X71
X71 RoboTeam interface"
Page 75)
RoboTeam start-up jumpers
X57
29 Digital I/O modules and bus (>>> 6.7.1 "Digital I/O mod-
coupler ules and bus coupler"
Page 54)
30 E67 interface (>>> 6.17 "Interface E67"
Page 76)
31 Performance Level (>>> 6.18 "Performance
level" Page 82)

6.1 Discrete interfaces for safety options

6.1.1 SafeRobot interface X13

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
SafeSingleBrake is installed and the interface has been configured
using the technology package. Configuration of the interface is described in
the SafeRangeMonitoring, SafeOperation or SafeSingleBrake documenta-
tion.

Contact diagram
X13

Fig. 6-1: Contact diagram

 X13, mating connector: Han 108DD with a male insert

 Housing size: 24B
 Cable gland M32

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 6 Planning

 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 The technical data for the inputs can be found in the section (>>> "SIB inputs"
allocation X13, Page 28).
inputs
Pin Description Function
1/3/5/ Test output A Makes the pulsed voltage avail-
7/9/1 able for the individual interface
(test signal)
1/13/ inputs of channel A.
15
19/21 Test output B Makes the pulsed voltage avail-
/23/2 able for the individual interface
(test signal)
5/27/ inputs of channel B.
29/31
/33
2 Reduced velocity channel A -
4 Monitoring space 12, channel A -
6 Monitoring space 13, channel A Programmable to SBH 3 chan-
nel A in WorkVisual (only under
KSS 8.3)
8 Monitoring space 14, channel A Programmable to SBH 4 chan-
nel A in WorkVisual (only under
KSS 8.3)
10 Monitoring space 15, channel A Programmable to SBH 5 chan-
nel A in WorkVisual (only under
KSS 8.3)
12 Monitoring space 16, channel A Programmable to SBH 6 chan-
nel A in WorkVisual (only under
KSS 8.3)
14 Safe operational stop, axis -
group 1, channel A
16 Safe operational stop, axis -
group 2, channel A
20 Reduced velocity, channel B -
22 Monitoring space 12, channel B -
24 Monitoring space 13, channel B Programmable to SBH 3 chan-
nel B in WorkVisual (only under
KSS 8.3)
26 Monitoring space 14, channel B Programmable to SBH 4 chan-
nel B in WorkVisual (only under
KSS 8.3)
28 Monitoring space 15, channel B Programmable to SBH 5 chan-
nel B in WorkVisual (only under
KSS 8.3)
30 Monitoring space 16, channel B Programmable to SBH 6 chan-
nel B in WorkVisual (only under
KSS 8.3)

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Pin Description Function

32 Safe operational stop, axis -
group 1, channel B
34 Safe operational stop, axis -
group 2, channel B

In the cabling for the input signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the voltages (e.g. separate cabling of input signals and test signals).

Connector pin The technical data for the outputs can be found in the section (>>> "SIB out-
allocation X13, puts" Page 27).
outputs
Pin Description
37 MR1 alarm space input, channel A
38 MR1 alarm space output, channel A
39 MR2 alarm space input, channel A
40 MR2 alarm space output, channel A
41 MR3 alarm space input, channel A
42 MR3 alarm space output, channel A
43 MR4 alarm space input, channel A
44 MR4 alarm space output, channel A
45 MR5 alarm space input, channel A
46 MR5 alarm space output, channel A
47 MR6 alarm space input, channel A
48 MR6 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
52 RR robot referenced, output, channel A
55 MR1 alarm space input, channel B
56 MR1 alarm space output, channel B
57 MR2 alarm space input, channel B
58 MR2 alarm space output, channel B
59 MR3 alarm space input, channel B
60 MR3 alarm space output, channel B
61 MR4 alarm space input, channel B
62 MR4 alarm space output, channel B
63 MR5 alarm space input, channel B
64 MR5 alarm space output, channel B
65 MR6 alarm space input, channel B
66 MR6 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,
suitable measures must be taken to prevent a cross-connection be-
tween the output signals of a channel (e.g. separate cabling).

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6.1.1.2 X13 SafeRangeMonitoring interface

Connector pin The technical data for the inputs can be found in the section (>>> "SIB inputs"
allocation X13, Page 28).
inputs
Pin Description Function
1/3/5/ Test output A Makes the pulsed voltage avail-
7/9/1 able for the individual interface
(test signal)
1/13/ inputs of channel A.
15
19/21 Test output B Makes the clocked voltage
/23/2 available for the individual
(test signal)
5/27/ interface inputs of channel B.
29/31
/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 -

In the cabling for the input signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the voltages (e.g. separate cabling of input signals and test signals).

Connector pin The technical data for the outputs can be found in the section (>>> "SIB out-
allocation X13, puts" Page 27).
outputs
Pin Description
37 MR1 alarm space input, channel A
38 MR1 alarm space output, channel A
39 MR2 alarm space input, channel A
40 MR2 alarm space output, channel A
41 MR3 alarm space input, channel A
42 MR3 alarm space output, channel A
43 MR4 alarm space input, channel A
44 MR4 alarm space output, channel A
45 MR5 alarm space input, channel A
46 MR5 alarm space output, channel A
47 MR6 alarm space input, channel A
48 MR6 alarm space output, channel A

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Pin Description
49 Safe monitoring active, input, channel A
50 Safe monitoring active, output, channel A
51 RR robot referenced, input, channel A
52 RR robot referenced, output, channel A
55 MR1 alarm space input, channel B
56 MR1 alarm space output, channel B
57 MR2 alarm space input, channel B
58 MR2 alarm space output, channel B
59 MR3 alarm space input, channel B
60 MR3 alarm space output, channel B
61 MR4 alarm space input, channel B
62 MR4 alarm space output, channel B
63 MR5 alarm space input, channel B
64 MR5 alarm space output, channel B
65 MR6 alarm space input, channel B
66 MR6 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,
suitable measures must be taken to prevent a cross-connection be-
tween the output signals of a channel (e.g. separate cabling).

6.1.1.3 X13 SafeSingleBrake interface

Connector pin The technical data for the inputs can be found in the section (>>> "SIB inputs"
allocation X13, Page 28).
inputs
Pin Description Function
1/3/5/ Test output A Makes the pulsed voltage avail-
7/9/1 able for the individual interface
(test signal)
1/13/ inputs of channel A.
15
19/21 Test output B Makes the pulsed voltage avail-
/23/2 able for the individual interface
(test signal)
5/27/ inputs of channel B.
29/31
/33
2 Spare -
4 Spare -
6 Safe operational stop, axis -
group 3, channel A
8 Safe operational stop, axis -
group 4, channel A
10 Safe operational stop, axis -
group 5, channel A
12 Safe operational stop, axis -
group 6, channel A

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Pin Description Function

14 Safe operational stop, axis -
group 1, channel A
16 Safe operational stop, axis -
group 2, channel A
20 Spare -
22 Spare -
24 Safe operational stop, axis -
group 3, channel B
26 Safe operational stop, axis -
group 4, channel B
28 Safe operational stop, axis -
group 5, channel B
30 Safe operational stop, axis -
group 6, channel B
32 Safe operational stop, axis -
group 1, channel B
34 Safe operational stop, axis -
group 2, channel B

In the cabling for the input signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the voltages (e.g. separate cabling of input signals and test signals).

Connector pin The technical data for the outputs can be found in the section (>>> "SIB out-
allocation X13, puts" Page 27).
outputs
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
49 Safe monitoring active, input, channel A
50 Safe monitoring active, output, channel A
51 Spare
52 Spare
55 Spare
56 Spare
57 Spare
58 Spare
59 Spare
60 Spare
61 Spare

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Pin Description
62 Spare
63 Spare
64 Spare
65 Spare
66 Spare
67 Safe monitoring active, input, channel B
68 Safe monitoring active, output, channel B
69 Spare
70 Spare

In the cabling for the output signals and test signals in the system,
suitable measures must be taken to prevent a cross-connection be-
tween the output signals of a channel (e.g. separate cabling).

6.1.1.4 Wiring examples for safe inputs and outputs

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 floating
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 outputs
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 Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.

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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 outputs.
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 cus-
tomer must be monitored externally for cross-connection.

Fig. 6-4: Connection schematic for safe output

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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
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 Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.

6.1.2 X53 “Drives ready” lamp

Description For operation in compliance with ANSI/UL 1740, a “Drives ready” lamp must
be mounted on the system or the manipulator. The lamp is connected to inter-
face X53 on the robot controller. It lights up when the machine is ready to
move. The lamp can be adapted to the specific circumstances of the system
by means of a connecting cable kit.

Necessary  Female and male connector, 5-pole

equipment

Fig. 6-5: Contact diagram

Connector pin Pin Description

allocation X53
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.

Connector pin Pin Description

allocation
1 TA24V A
2 E_REF_A_24V
3 GND
4 TA24V B
5 E_REF_B_24V

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6.1.4 X58 external enabling switches

Description Interface X58 is used for connecting external enabling switches.

Necessary  Article 00277097 enabling switch at X58 with L = 20 type: 2-channel en-
equipment abling switch with 20 m connecting cable including Han 8D-F connector

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

 Recommended wire cross-section: 0.75 mm2

Connector pin For connection of the external 2-channel enabling switch 1 with floating con-
allocation X58 tacts.

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.

Pin Description Function

3 Test output A Makes the pulsed voltage avail-
4 able for the individual interface
(test signal)
inputs of channel A.
7 Test output B Makes the clocked voltage
8 available for the individual
(test signal)
interface 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 effec-
tive 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 effec-
tive in TEST modes.

Function of  External enabling 1

external axis Enabling switch must be pressed for jogging in T1 or T2. Input is closed.
enabling switch  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.

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Function External External

Switch position
(only active for T1 and T2) enabling 1 enabling 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 pow-
er supply to a switch.

Necessary  X11, mating connector: Han 108DD with a male insert

equipment

Fig. 6-7: Contact diagram

 Housing size: 24B

 Cable gland M32
 Cable diameter 14-21 mm
 Cable cross-section ≥ 1 mm2

Connector pin Pin Description

allocation X11
105 +24 V external
106 0 V external
107 +24 V internal
108 0 V internal

6.2.2 X55 external power supply

Description The following couplers can be supplied with power via connector X55:
 Switch
 VARAN slave
 EtherCAT bridge

Necessary  Male insert, HAN 8D

equipment

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Fig. 6-8: Contact diagram, view from contact side

 Cable clamping range: Ø9 ... Ø13 mm

 Recommended wire cross-section: 1 mm 2

Connector pin
Pin Description
allocation X55
5 +24 V external
6 0 V external
7 +24 V internal
8 0 V internal
- PE

6.3 Load voltages

6.3.1 X11 load voltages US1 and 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 deactivated.
This function exists in the following three variants and is set in the safety con-
figuration:
 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 between
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 voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

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If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  X11, mating connector: Han 108DD with a male insert

equipment

Fig. 6-9: Contact diagram

 Housing size: 24B

 Cable gland M32
 Cable diameter 14-21 mm
 Cable cross-section ≥ 1 mm2

Connector pin
Pin Signal Description
allocation X11
91 Load voltage US1 24 V internal / 5 A non-
switched
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 43)
94 0 V internal

The load voltage US2 is switched via contactors Q5 and Q6. Fuses F6 (US1)
and F301 (US2) are located on the CCU_SR.

6.3.2 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 deactivated.
This function exists in the following three variants and is set in the safety con-
figuration:
 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 between
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.

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In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Male insert, Han Q7/0

equipment

Fig. 6-10: Contact diagram, view from contact side

 Cable clamping range: Ø9 ... Ø13 mm

 Recommended wire cross-section: 1.5 mm 2

Connector pin
Pin Description
allocation X56
1 US1 +24 V / 5 A (F6)
2 US1 0 V
3 US2 +24 V / 7 A (F301)
4 US2 0 V
- PE

The load voltage US2 is switched via contactors Q5 and Q6. The fuses are lo-
cated on the CCU_SR.

6.3.3 X54 interface 27V PWR US1

Description Interface X54 provides the unswitched load voltage US1.

Necessary  Male insert, Han Q7/0

equipment

Fig. 6-11: Contact diagram, view from contact side

 Cable clamping range: Ø9 ... Ø13 mm

 Recommended wire cross-section: 1.5 mm 2

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Connector pin
Pin Description
allocation X54
1 US1 +24 V / 5 A
2 US1 0 V

The load voltage US2 is switched via contactors Q5 and Q6. The fuses are lo-
cated on the CCU_SR.

6.3.4 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

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 in-
put “Peripheral contactor (US2)” in the PROFIsafe or CIP Safety telegram.

KRC In this configuration, the US2 contactor can be checked by opening the oper-
ator safety device (safeguard) in “Automatic” or “Automatic External” mode
and releasing the enabling switch in “T1” or “T2” mode.

6.3.5 X14B interface 27V PWR US1/US2

Description
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Connector, 7/8" 5-pole

equipment

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Fig. 6-12: Contact diagram, view from contact side

 Cable clamping range: Ø10 ... Ø12 mm

 Maximum cable cross-section: AWG16

Connector pin Pin Description

allocation X14B
2 US1 +24 V / 5 A
4 US1 0 V
3 PE
1 US2 +24 V / 7 A
5 US2 0 V

The load voltage US2 is switched via contactors Q5 and Q6. The fuses are lo-
cated on the CCU_SR.

6.3.6 X14B interface 27V PWR US1

Necessary  Connector, 7/8" 5-pole

equipment

Fig. 6-13: Contact diagram, view from contact side

 Cable clamping range: Ø10 ... Ø12 mm

 Maximum cable cross-section: AWG16

Connector pin Pin Description

allocation X14B
2 US1 +24 V / 5 A
4 US1 0 V
3 PE

6.3.7 X14B interface 27V PWR NA US1/US2

Description
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

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If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Connector, 7/8" 4-pole

equipment

Fig. 6-14: Contact diagram, view from contact side

 Cable clamping range: Ø10 ... Ø14 mm

 Maximum cable cross-section: AWG16

Connector pin
Pin Description
allocation X14B
2 US1 +24 V / 5 A
3 US1 0 V
1 US2 +24 V / 7 A
4 US2 0 V

The load voltage US2 is switched via contactors Q5 and Q6. The fuses are lo-
cated on the CCU_SR.

6.3.8 X14B interface 24V PWR NA US1/US2

Description
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Connector, 7/8" 4-pole

equipment

Fig. 6-15: Contact diagram, view from contact side

 Cable clamping range: Ø10 ... Ø14 mm

 Maximum cable cross-section: AWG18

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Connector pin
Pin Description
allocation X14B
1 +24V US2
2 +24V US1
3 0V US1
4 0V US2

The load voltage US2 is switched via contactors Q5 and Q6. The fuses are lo-
cated on the CCU_SR.

6.4 Infeed

6.4.1 X14A interface 27V PWR IN NA

Description Interface X14A is used for the internal and external power supply of the inter-
nal switch.

Necessary  Connector, 7/8" 4-pole

equipment

Fig. 6-16: Contact diagram, view from contact side

 Cable clamping range: Ø10 ... Ø14 mm

 Maximum cable cross-section: AWG18

Connector pin
Pin Description
allocation X14A
1 24V external
2 0 V external
4 24V internal
3 0V internal

6.4.2 X14A interface 27V PWR IN

Description Interface X14A is used for the internal and external power supply of the inter-
nal switch.

Necessary  Connector, 7/8" 5-pole

equipment

Fig. 6-17: Contact diagram, view from contact side

 Cable clamping range: Ø10 ... Ø14 mm

 Maximum cable cross-section: AWG18

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Connector pin
Pin Description
allocation X14A
1 24V external
2 0 V external
3 PE
4 24V internal
5 0V internal

6.4.3 X14A interface 24V PWR IN NA

Description Interface X14A is used for the internal and external power supply of the inter-
nal switch.

Necessary  Connector 7/8" 4-pole

equipment

Fig. 6-18: Contact diagram, view from contact side

 Cable clamping range: Ø10 ... Ø14 mm

 Maximum cable cross-section: AWG16

Connector pin
Pin Description
allocation X14A
2 24V internal
3 0V internal

6.5 Ethernet interfaces

6.5.1 X63 PROFINET SYNC interface

Description The interface PROFINET SYNC X63 is connected to the KUKA Line Interface
(KLI) on the control PC via the interface module IM151-3 PN (A80) and en-
ables synchronization with an external controller.

Necessary  RJ45 connector

equipment

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Fig. 6-19: RJ-45 pin assignment

 Recommended connecting cable: PROFINET-compatible, min. category

CAT 5e
 Maximum cable cross-section: AWG22

Connector pin Pin Description

allocation X63
1 TD+
2 TD-
3 RD+
6 RD-
- PE

6.5.2 KONI interface X64.1, X64.2 and X64.3

Description The KONI interfaces X64.1, X64.2 and X64.3 are connected to the KUKA Line
Interface (KLI) on the control PC via the interface module IM151-3 PN (A80)
and enables synchronization with an external controller.

Necessary  RJ45 connector

equipment

Fig. 6-20: RJ-45 pin assignment

 Recommended connecting cable: PROFINET-compatible, min. category

CAT 5e
 Maximum cable cross-section: AWG22

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Connector pin
Pin Description
allocation X64.1,
1 TD+
X64.2 and X64.3
2 TD-
3 RD+
6 RD-
4 C+
5 C-
7 D+
8 D-

6.6 EtherCAT interfaces

6.6.1 X65 EtherCAT interface

Description Connector X65 in the connection panel is the interface for connection of Ether-
CAT slaves outside the robot controller. The EtherCAT line is routed out of the
robot controller.

The EtherCAT devices must be configured with WorkVisual.

Necessary  RJ45 connector

equipment

Fig. 6-21: RJ-45 pin assignment

 Recommended connecting cable: PROFINET-compatible, min. category

CAT 5e
 Maximum cable cross-section: AWG22

Connector pin Pin Description

allocation X65 via
1 TPFO_P
CIB
2 TPFO_N
3 TPFI_P
6 TPFI_N

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Connector pin
Pin Description
allocation X65 via
1 TPFO_P
bus coupler
2 TPFO_N
3 TPFI_P
6 TPFI_N

6.6.2 X67.1 and X67.2 EtherCAT bridge interfaces

Description EtherCAT bridge interfaces X67.1 and X67.2 enable communication between
an EtherCat master and the robot controller via the EtherCat bridge.

Necessary  Connector V14 RJ45

equipment

Fig. 6-22: RJ-45 pin assignment

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5e
 Maximum cable cross-section: AWG22

Connector pin
Pin Description
allocation X67.1
1 TD+ Master IN
2 TD- Master IN
3 RD+ Master IN
6 RD- Master IN
- PE

Connector pin
Pin Description
allocation X67.2
1 TD+ Master OUT
2 TD- Master OUT
3 RD+ Master OUT
6 RD- Master OUT
- PE

6.7 EtherCAT input/output modules

The EtherCAT devices must be configured with WorkVisual.

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6.7.1 Digital I/O modules and bus coupler

Overview Step Description Information

1 EK1100 bus coupler (>>> 6.7.2 "Bus coupler
EK1100" Page 55)
2 EL9100 infeed (>>> 6.7.3 "Infeed EL9100"
Page 56)
3 EL1809 16-channel inputs (>>> 6.7.4 "16-channel inputs
EL1809" Page 56)
4 EL1889 16 channel input, (>>> 6.7.5 "16-channel inputs
negative switching EL1889, negative switching"
Page 57)
5 EL2024 4-channel 2 A outputs (>>> 6.7.6 "4-channel 2 A
outputs, EL2024" Page 58)
6 EL2622 2-channel 5 A relay (>>> 6.7.7 "2-channel relay
outputs outputs EL2622" Page 59)
7 EL2809 16-channel 0.5 A out- (>>> 6.7.8 "16-channel out-
puts puts EL2809" Page 59)
8 EL2889 16 channel output, (>>> 6.7.9 "16-channel out-
negative switching puts EL2889, negative switch-
ing" Page 60)
9 EL6692 EtherCAT bridge (>>> 6.8.1 "EtherCAT bridge
EL6692" Page 61)
10 EL6695 EtherCAT bridge (>>> 6.8.2 "EtherCAT bridge
EL6695-1001" Page 62)
11 EL6731 PROFIBUS master (>>> 6.8.3 "PROFIBUS mas-
ter/slave EL6731(0010)"
EL6731.0010 PROFIBUS
Page 62)
slave
12 EL6752 DeviceNet mas- (>>> 6.8.4 "DeviceNet mas-
ter/slave ter/slave EL6752(0010)"
Page 63)
13 VARAN slave (>>> 6.8.5 "VARAN slave bus
coupler" Page 63)

The EtherCAT devices must be configured with WorkVisual.

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6.7.2 Bus coupler EK1100

Overview

Fig. 6-23: 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
0V 5 0 V supply to bus coupler
+24 V ext. 1- 6 +24 V external power supply for bus coupler ref-
16 erence point
0 V ext. 1-16 7 0 V external power supply for bus coupler refer-
ence point

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6.7.3 Infeed EL9100

Overview

Fig. 6-24: Connections, infeed

1 Infeed 24 V (+) 3 PE infeed

2 Infeed 0 V (-)

6.7.4 16-channel inputs EL1809

Overview

Fig. 6-25: Connections, 16-channel inputs

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Signal Item Description

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
Input 4 4 Digital input 4
Input 5 5 Digital input 5
Input 6 6 Digital input 6
Input 7 7 Digital input 7
Input 8 8 Digital input 8
Input 9 9 Digital input 9
Input 10 10 Digital input 10
Input 11 11 Digital input 11
Input 12 12 Digital input 12
Input 13 13 Digital input 13
Input 14 14 Digital input 14
Input 15 15 Digital input 15
Input 16 16 Digital input 16

6.7.5 16-channel inputs EL1889, negative switching

Overview

Fig. 6-26: Connections, 16-channel inputs

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Signal Item Description

Input 1 1 Digital input 1 Reference point 24 V
Input 2 2 Digital input 2 external 1-16
Input 3 3 Digital input 3
Input 4 4 Digital input 4
Input 5 5 Digital input 5
Input 6 6 Digital input 6
Input 7 7 Digital input 7
Input 8 8 Digital input 8
Input 9 9 Digital input 9
Input 10 10 Digital input 10
Input 11 11 Digital input 11
Input 12 12 Digital input 12
Input 13 13 Digital input 13
Input 14 14 Digital input 14
Input 15 15 Digital input 15
Input 16 16 Digital input 16

6.7.6 4-channel 2 A outputs, EL2024

Overview

Fig. 6-27: Connections, 4-channel 2 A outputs

1 Output 1 5 Output 2
2 0V 6 0V
3 0V 7 0V
4 Output 3 8 Output 4

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6.7.7 2-channel relay outputs EL2622

Overview

Fig. 6-28: Connections, 2-channel relay outputs

1 PE 4 Output 1
2 Power contact N 5 Output 2
3 Power contact L

6.7.8 16-channel outputs EL2809

Overview

Fig. 6-29: Connections, 16-channel 0.5 A outputs

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Signal Item Description

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
Output 4 4 Digital output 4
Output 5 5 Digital output 5
Output 6 6 Digital output 6
Output 7 7 Digital output 7
Output 8 8 Digital output 8
Output 9 9 Digital output 9
Output 10 10 Digital output 10
Output 11 11 Digital output 11
Output 12 12 Digital output 12
Output 13 13 Digital output 13
Output 14 14 Digital output 14
Output 15 15 Digital output 15
Output 16 16 Digital output 16

6.7.9 16-channel outputs EL2889, negative switching

Overview

Fig. 6-30: Connections, 16-channel 0.5 A outputs

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Signal Item Description

Output 1 1 Digital output 1 0.5 A per output,
Output 2 2 Digital output 2 0 V external
power supply 1-16
Output 3 3 Digital output 3
Output 4 4 Digital output 4
Output 5 5 Digital output 5
Output 6 6 Digital output 6
Output 7 7 Digital output 7
Output 8 8 Digital output 8
Output 9 9 Digital output 9
Output 10 10 Digital output 10
Output 11 11 Digital output 11
Output 12 12 Digital output 12
Output 13 13 Digital output 13
Output 14 14 Digital output 14
Output 15 15 Digital output 15
Output 16 16 Digital output 16

6.8 EtherCAT gateways

The EtherCAT devices must be configured with WorkVisual.

6.8.1 EtherCAT bridge EL6692

Overview

Fig. 6-31: Connections for EtherCAT bridge EL6692

1 24 V supply
2 EtherCAT Out
3 EtherCAT In

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6.8.2 EtherCAT bridge EL6695-1001

Overview

Fig. 6-32: 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

variant and can be used as a safe module. This variant is exclusively
available from KUKA Roboter GmbH.

6.8.3 PROFIBUS master/slave EL6731(0010)

Overview

Fig. 6-33: Connections for PROFIBUS master/slave EL6731

1 Field bus connection

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6.8.4 DeviceNet master/slave EL6752(0010)

Overview

Fig. 6-34: Connections for DeviceNet master/slave EL6752

1 Field bus connection

6.8.5 VARAN slave bus coupler

Overview

Fig. 6-35: 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

6.9 Fast Measurement

6.9.1 X33 Fast Measurement inputs (option)

Description Fast measurement is activated with $MEAS_PULSE by means of an interrupt.

When the interrupt is activated, $MEAS_PULSE must have the value “false”,

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otherwise an acknowledgement message is generated and the program is

stopped.

Necessary  Cable clamping range: Ø6 ... Ø10 mm

equipment  Recommended cable cross-section: 1 mm 2

Fig. 6-36: Contact diagram, X33, view from contact side

Connector pin
Pin Description
allocation X33
1 Fast Measurement 1
2 Fast Measurement 2
3 Fast Measurement 3
4 Fast Measurement 4
5 Spare
6 +24V-P
7 GND-Input
8 0V-P

6.9.1.1 Power supply for Fast Measurement

Internal power If the sensors for Fast Measurement are supplied with power by the robot con-
supply troller (pin 6 +24V-P, pin 8 GND-P), pins 7 and 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).
The diagram (>>> Fig. 6-37 ) illustrates the internal voltage supply.

Fig. 6-37: Internal power supply for “Fast Measurement”

1 Sensor 1 4 Sensor 4

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2 Sensor 2 5 Jumper between GND-INPUT

and 0V-P in connector X33
3 Sensor 3

External power If the sensors for Fast Measurement are supplied externally with power (not
supply via X33 of the robot controller), the reference ground of the sensors must be
connected to pin 7 GND-Input.

Fig. 6-38: 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

6.10 Euromap interfaces

6.10.1 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  RJ45 connector

equipment

Fig. 6-39: RJ-45 pin assignment

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5e
 Maximum cable cross-section: AWG22

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Connector pin
Pin Description
allocation X67.1
1 TD+ VARAN IN
2 TD- VARAN IN
3 RD+ VARAN IN
6 RD- VARAN IN
- PE

Connector pin Pin Description

allocation X67.2
1 TD+ VARAN OUT
2 TD- VARAN OUT
3 RD+ VARAN OUT
6 RD- VARAN OUT
- PE

6.11 DeviceNet interfaces

6.11.1 DeviceNet interfaces, overview

The following DeviceNet variants are available:

 X14A DeviceNet Master
X14B load voltage US1/US2 X14B
 X14A DeviceNet Master
X14B load voltage US1/US2
X14C DeviceNet Slave In
 X14A DeviceNet Master
X14B load voltage US1/US2
X14C DeviceNet Slave In
X14D DeviceNet Slave Out

6.11.1.1 X14A and X14B DeviceNet Master

Description
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Connector, 7/8" 5-pole

equipment

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Fig. 6-40: Contact diagram, X14A, view from contact side

 Cable clamping range: Ø10 ... Ø12 mm

 Maximum cable cross-section: AWG16
 Connector, 7/8" 4-pole

Fig. 6-41: Contact diagram, X14A, view from contact side

 Cable clamping range: Ø10 ... Ø12 mm

 Maximum cable cross-section: AWG16

Connector pin Pin Description

allocation X14A
1 DRAIN
2 24 V
3 0V
4 CAN_H
5 CAN_L

Connector pin Pin Description

allocation X14B
2 US1 +24 V/5 A
4 US1 0 V
1 US2 +24 V/7 A
3 US2 0 V

The load voltage US2 is switched via contactors Q5 and Q6. The fuses are lo-
cated on the CCU_SR.

6.11.1.2 DeviceNet Slave X14C

Description
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

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The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Connector 7/8" 5-pole

equipment

Fig. 6-42: Contact diagram, X14C, view from contact side

 Cable clamping range: Ø10 ... Ø12 mm

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

Connector pin Pin Description

allocation X14C
1 DRAIN
2 24 V
3 0V
4 CAN_H
5 CAN_L

6.11.1.3 X14C and X14D DeviceNet interface

Description
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Connector 7/8" 5-pole

equipment

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Fig. 6-43: Contact diagram, X14C, view from contact side

 Cable clamping range: Ø10 ... Ø12 mm

 Recommended connecting cable: DeviceNet cable 2xAWG17, 2xAWG20,
drain AWG20
 Connector, 7/8" 5-pole

Fig. 6-44: Contact diagram, X14D, view from contact side

 Cable clamping range: Ø10 ... Ø12 mm

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

Connector pin Pin Description

allocation X14C,
1 DRAIN
X14D
2 24 V
3 0V
4 CAN_H
5 CAN_L

6.12 PROFIBUS interfaces

6.12.1 X15A and X15B PROFIBUS interface

Description Power supply to X15A and X15B can be carried out either directly, from an ex-
ternal power supply, or by jumpering the internal voltage. If connector 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  Male connector M23: Bus connector, 17-pole, P-part

equipment

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Fig. 6-45: Contact diagram, X15A, view from contact side

 Cable clamping range: Ø9 ... Ø14.7 mm

 Recommended connecting cable: Multibus cable
 Female connector M23: Bus connector, 12-pole, E-part

Fig. 6-46: Contact diagram, X15B, view from contact side

 Cable clamping range: Ø9 ... Ø14.7 mm

 Recommended connecting cable: Multibus cable

Connector pin Pin Description

allocation X15A,
1 0V
X15B
4 24 V DC
5 PE
7 PROFI A
8 PROFI B

6.12.2 X61 PROFIBUS master

Description
In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.3.4 "Checking the US2 function, load voltage con-
tactor" Page 46).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Female connector M23: Bus connector, 17-pole, E-part

equipment

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Fig. 6-47: Contact diagram, view from contact side

 Cable clamping range: Ø9 ... Ø14.7 mm

 Recommended connecting cable: Multibus cable

Connector pin Pin Description

allocation X61
11 PROFI A
6 PROFI B
5 PE
4 US1 +24 V
1 US1 0 V
3 US2 +24 V
2 US2 0 V

The load voltage US2 is switched via contactors Q5 and Q6. The fuses are lo-
cated on the CCU_SR.

6.13 Floating contacts

6.13.1 X31, X32 floating contacts

Description Interfaces X31 and X32 are floating contacts and are used to connect custom-
er-specific interfaces.

Necessary  Female and male connector, M12, A-coded

equipment

Fig. 6-48: Contact diagram, view from socket side

 Recommended connecting cable: 0.14...0.34 mm2

 Maximum cable cross-section: AWG22

Connector pin Pin Description

allocation X31,
1 Contactor US2 output 1
X32
2 Contactor US2 input 1
3 Contactor US2 output 2
4 Contactor US2 input 1

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6.14 Cable inlet X51

Description Four-fold cable inlet for digital inputs/outputs

Overview

Fig. 6-49: Cable inlet X51

1 Cable inlet clamping range 4.5 ... 10 mm

2 Cable inlet clamping range 9 ... 15 mm

6.15 KLI interfaces

Overview Step Description Information

1 KLI interface X66 (>>> 6.15.1 "X66 Ethernet
interface (RJ45)" Page 72)
2 KLI interface X67 (>>> 6.15.2 "X67.1, X67.2
and X67.3 KLI interfaces"
Page 73)
3 CSP interface (>>> 6.15.3 "KLI interface on
CSP" Page 73)

6.15.1 X66 Ethernet interface (RJ45)

Description Interface X66 is used for connecting an external computer to the KUKA Line
Interface for the purpose of installation, programming, debugging and diagno-
sis.

Necessary  RJ45 connector

equipment

Fig. 6-50: RJ-45 pin assignment

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5E

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 Maximum cable cross-section: AWG22

Connector pin
10BASE-T, 100BASE-TX allo-
allocation X66 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-

6.15.2 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 computer to
the robot controller.

Necessary  RJ45 connector

equipment

Fig. 6-51: RJ-45 pin assignment

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5E
 Maximum cable cross-section: AWG22

Connector pin
Pin Description
allocation X67.1,
1 TD+
X67.2, X67.3
2 TD-
3 RD+
6 RD-

6.15.3 KLI interface on CSP

Description The KLI interfaces on the CSP can be used to connect the KUKA Line Inter-
face from the switch to the system, for example, or to connect a computer to
the robot controller.

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Necessary  RJ45 connector

equipment

Fig. 6-52: RJ-45 pin assignment

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5E
 Maximum cable cross-section: AWG22

Connector pin Pin Description

allocation,
1 TD+
KLI/KSI
2 TD-
3 RD+
6 RD-

6.15.4 X17A, X17B, X17C KLI interface

Description The Ethernet interfaces X17A, X17B and X17C can be used to connect the
KUKA Line Interface to the system, for example, or to connect a computer to
the robot controller.

Necessary  M12 D-coded connector

equipment

Fig. 6-53: Contact diagram, view from contact side

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5
 Maximum cable cross-section: AWG20

Connector pin Pin Description

allocation X17A,
1 TD+
X17B, X17C
2 TD-
3 RD+
4 RD-

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6.15.5 X17D, X17E, X17F KLI interface

Description The Ethernet interfaces X17D, X17E and X17F can be used to connect the
KUKA Line Interface to the system, for example, or to connect a computer to
the robot controller.

Necessary  M12 D-coded connector

equipment

Fig. 6-54: Contact diagram, view from contact side

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5
 Maximum cable cross-section: AWG20

Connector pin Pin Description

allocation X17D,
1 TD+
X17E, X17F
2 TD-
3 RD+
4 RD-

6.16 X70 and X71 RoboTeam interface

Description It is only possible to use the interface if the technology package RoboTeam is
installed.

Required material  M12 D-coded connector

X70 and X71

Fig. 6-55: Contact diagram, view from contact side

 Recommended connecting cable: Ethernet-compatible, min. category

CAT 5
 Maximum cable cross-section: AWG22

Connector pin Pin Description

allocation X70
1 TPFO_P
RoboTeam IN
2 TPFO_N
3 TPFI_P
4 TPFI_N

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Connector pin
Pin Description
allocation X70
1 TPFO_P
RoboTeam OUT
2 TPFO_N
3 TPFI_P
4 TPFI_N

6.16.1 X57 interface, internal power supply

Description The interface can only be used if the RoboTeam technology package is in-
stalled and is used for the internal power supply.

Materials  Connector Han3A

required X57

Fig. 6-56: Contact diagram, X57, view from contact side

 Cable clamping range: Ø9 ... Ø13 mm

 Recommended wire cross-section: 1.5 mm 2

Connector pin
Pin Description
allocation X57
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 in-
ternal power supply.

The wire jumpers are contained loose in connector bypack X57.

6.17 Interface E67

Overview Step Description Information

1 E67 interface
2 X27 E-STOP and safeguard (>>> 6.17.2 "X27 interface"
Page 78)
3 X51 cable inlet (>>> 6.14 "Cable inlet X51"
Page 72)
4 X62 PROFIBUS/load volt- (>>> 6.17.3 "X62 load volt-
age US1/US2 age US1/US2" Page 81)
5 X68 Extension Bus (>>> 6.17.4 "X68 interface"
Page 82)

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6.17.1 Interface E67

Description Interface E67 serves as a communication and safety interface for an injection
molding machine.

Necessary  Screwed connection: M32

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

Fig. 6-57: Contact diagram, E67, male connector (view from contact side)

 Recommended cable cross-section: 0.75 mm 2

 Mating connector: Han 25D with a female insert

Fig. 6-58: Contact diagram, E67, female connector (view from contact
side)

Connector pin Pin Description Function

allocation
ZA1 Test output A Makes the pulsed voltage avail-
ZA3 able for the individual interface
(test signal)
inputs of channel A.
ZA2 Test output B Makes the clocked voltage
ZA4 available for the individual
(test signal)
interface inputs of channel B.
ZA9 +24 V 24 V control voltage for supply
ZC9 to external devices, max. 2 A
0V
This voltage is available to the
customer
A1/C Local E-STOP, channel A Output, floating contacts from
1 internal E-STOP, (>>> "SIB
A2/C Local E-STOP, channel B outputs" Page 27)
2 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 28)
Triggering of the E-STOP func-
tion in the robot controller
A3/C Mold area free A36 floating contacts to the
3 IMM

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Pin Description Function

C5/C Safeguard channel A Floating contacts to the IMM,
6 (>>> "SIB outputs" Page 27)
C7/C Safeguard channel B This interface deviates from the
8 standardized interface E67
ZC3 Safeguard channel A For connection of a dual-chan-
ZC4 Safeguard channel B nel safety gate lock, (>>> "SIB
inputs" Page 28)
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 24 V input A34 I4
position
ZB2 Fully automatic IMM 24 V input A34 I5
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
ZB6 Core pullers free 1 pos. 2 24 V input A34 I9
ZB7 Core pullers free 2 pos. 1 24 V input A34 I10
ZB8 Core pullers free 2 pos. 2 24 V input A34 I11
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
B6 Core pullers free 1 pos. 2 24 V output A38 O7
B7 Core pullers free 2 pos. 1 24 V output A38 O8
B8 Core pullers free 2 pos. 2 24 V output A38 O9
A9 + 24 V Power supply, 24 V, external to
C9 IMM
0V

6.17.2 X27 interface

The X27 safety interface is wired internally to the SIB.

Contact diagram
X27

Fig. 6-59: Contact diagram, view from contact side

 Mating connector: Han 40D with a male insert

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 Screwed connection: M32

 Cable diameter: 14-21 mm
 Recommended cable cross-section: 0.75 mm2

In the cabling for the input signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the voltages (e.g. separate cabling of input signals and test signals).

In the cabling for the output signals and test signals in the system,
suitable measures must be taken to prevent a cross-connection be-
tween the output signals of a channel (e.g. separate cabling).

Connector pin
Pin Description Function
allocation
A1 SIB test output A Makes the pulsed voltage avail-
A3 able for the individual interface
(test signal)
inputs of channel A.
A5
These signals may only be
mapped with the SIB.
B1 SIB test output B Makes the clocked voltage
B3 available for the individual
(test signal)
interface inputs of channel B.
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 acti-
vated monitoring is violated.
A6 Safety stop, Stop 2 channel A Safety stop (Stop 2) input for all
B6 Safety stop, Stop 2 channel B axes
Triggering of Stop 2 and activa-
tion of standstill monitoring at
standstill of all axes.
Stop 0 is initiated if the acti-
vated 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 28)
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
acknowledge button outside
the safety fence. This function
is deactivated on delivery.

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Pin Description Function

A7 Peri enabled channel A Output, floating contact
A8 (>>> "SIB outputs" Page 27)
B7 Peri enabled channel B (>>> "Signal “Peri enabled”
B8 (PE)" Page 80)
C1 Output, channel 1 (K 20) Output, test signal, chan-
D1 Output, channel 2 (K 20) nel 1/2 for C2/D2
C2 Input E-STOP, channel 1 (K 20) Connection for EMERGENCY
D2 Input E-STOP, channel 2 (K 20) STOP button on the robot
safety enclosure
Signal affects robot and IMM
C3 Output, channel 1 (K 21) Output, test signal, chan-
D3 Output, channel 2 (K 21) nel 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
(K 21) robot.
For IMMs, the E73 interface of
the IMM must be configured
with a separate door switch.

Operator safety The SIB input signal “Operator safety acknowledgement” (from the IMM) is
acknowl- switched via E67 and also via interface X27. The E67 standard does not in-
edgement clude an additional acknowledging signal for the operator safety acknowledge-
ment 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 quali-
fied 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 possi-
ble:
 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 safety
configuration

Signal “Peri The signal “Peri enabled” is set to 1 (active) if the following conditions are met:
enabled” (PE)  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.

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 Activation of the signal “Safe operational stop” with the manipulator sta-
tionary:
Release the brakes, switch drives to servo-control and monitor for restart.
“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.

6.17.3 X62 load voltage US1/US2

Description The load voltages are not switched, so that the valve terminal on the arm of
the manipulator is always energized.
If, due to a fault in the system cabling, there is a cross connection between
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 voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

Necessary  Female connector M23: Bus connector, 17-pole, E-part

equipment

Fig. 6-60: Contact diagram, view from contact side

 Cable clamping range: Ø9 ... Ø14.7 mm

 Recommended connecting cable: Multibus cable

Connector pin Pin Description

allocation X62
11 PROFI A
6 PROFI B
5 PE
4 US1 +24 V/ 5 A

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Pin Description
1 US1 0 V
3 U21 +24 V/ 7 A
2 U21 0 V

6.17.4 X68 interface

US1 0 V

Connector pin
Pin Description
allocation X68
1 TPFO_P
2 TPFO_N
3 TPFI_P
6 TPFI_N

6.18 Performance level

The safety functions of the robot controller conform to Category 3 and Perfor-
mance Level d according to EN ISO 13849-1.

6.18.1 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 E-STOP device
is 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 systems 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 controller
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

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 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 variants: TFO1; TFO2 < 2 x 10-7
KR C4 variants: TRE1; TRE2 < 1.7 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 < 1 x 10-7
VKR C4 Retrofit
 Without external EMERGENCY STOP and operator < 1 x 10-7
safety functions
 External EMERGENCY STOP and operator safety 5 x 10-7
functions
KR C4 Panel Mounted < 1 x 10-7
KR C4 compact < 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
Roboter GmbH.

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7 Maintenance
t

7.1 Safety Interface Board Extended

The maintenance work, tests and test cycles for the SIB Extended are speci-
fied in the operating instructions of the KR C4 robot controller.

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 8 KUKA Service

8 KUKA Service
A

8.1 Requesting support

v

Introduction This documentation provides information on operation and operator control,

and provides assistance with troubleshooting. For further assistance, please
contact your local KUKA subsidiary.

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

 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 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 modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
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 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
[email protected]

Australia KUKA Robotics Australia Pty Ltd

45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
[email protected]
www.kuka-robotics.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
[email protected]
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
[email protected]
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
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
[email protected]
www.kuka-robotics.com

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
[email protected]
www.kuka-roboter.de

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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
[email protected]
www.kuka.fr

India KUKA Robotics 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
[email protected]
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
[email protected]
www.kuka.it

Japan KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
[email protected]

Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

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 Optional Interfaces

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
[email protected]

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
[email protected]

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
[email protected]
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
[email protected]

Austria KUKA Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
[email protected]
www.kuka.at

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Poland KUKA Roboter Austria GmbH

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
[email protected]

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
[email protected]
www.kuka.com

Russia KUKA Robotics RUS

Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
[email protected]
www.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
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

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Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
[email protected]
www.kuka.es

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

Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
[email protected]
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
[email protected]
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
[email protected]

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Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com

UK KUKA Robotics UK Ltd

Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
[email protected]
www.kuka-robotics.co.uk

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 Index

Index
Symbols Digital I/O modules 16/16/4 22
“Drives ready” lamp, X53 40 Digital I/O modules, overview 54
Documentation, industrial robot 7
Numbers Dual NIC 8
2-channel relay outputs 59 Dynamic testing 39
24 V external power supply 26
24V PWR IN NA X14A 50 E
24V PWR NA US1/US2 X14B 48 E67 EtherCAT modules 24
27V PWR IN NA X14A 49 E67 interface 76, 77
27V PWR IN X14A 49 E67 switching devices 24
27V PWR NA US1/US2 X14B 47 E67 upper side connection panel 20
27V PWR US1 X14B 47 EA 9
27V PWR US1 X54 45 EDS 8
27V PWR US1/US2 X14B 46 EDS cool 8
EL1809 56
A EL1889 57
Assignment of slot 14 20 EL2024 58
Assignment of slot 15 21 EL2622 59
Assignment of slot 2 15 EL2809 59
Assignment of slot 3 17 EL2889 60
Assignment of slot 4 17 EL6692 61
Assignment of slot 5 19 EL6695 62
Assignment of slot 6 19 EL6731(0010) 62
EL6752 (0010) 63
B EL9100 56
BR M 8 EMC 8
Bus coupler EK1100 55 EMD 8
Bus coupler, overview 54 Enabling switches, external 41
EtherCAT bridge 61, 62
C EtherCAT bridge, external power supply 42
Cable inlet X51 72 EtherCAT interfaces 52
CCU 8 EtherCAT, gateways 61
CIB 8 Ethernet interface (RJ45), X66 72
CIP Safety 8 Ethernet interfaces 50
CK 8 Ethernet/IP 8
Connector pin allocation X27 79 Euromap interfaces 65
Connector pin allocation X42 40 External enabling switch, function 41
Connector pin allocation X54 46 External power supply 42
Connector X27 78 External power supply X33 65
Connector X62 81 External power supply, X11 42
Connector X68 82 External power supply, X55 42
Contact diagram X27 78 External voltage 27
CSP 8
F
D Fast Measurement, interfaces 63
Data cables 13 Floating contacts 71
DeviceNet interfaces 66
DeviceNet Master 66 G
DeviceNet master/slave 63 Gateways, EtherCAT 61
DeviceNet Slave 67
DeviceNet Slave IN and OUT 68 H
DeviceNet X14A 66 HMI 8
DeviceNet X14B 66
DeviceNet X14C 67, 68 I
DeviceNet X14D 68 Infeed 13, 49, 56
DeviceNet, interfaces 66 Inputs, 16-channel 56, 57
Digital I/O interface 32/32/4 23 Inputs, Fast Measurement 63
Digital I/O modules 16/16 21 Intended use 11

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Interface E67 76 Outputs, 4-channel, 2 A outputs 58

Interface X64.1 51 Overview, robot controller 13
Interface X64.2 51
Interface X64.3 51 P
Interface X70 75 PE cables 13
Interface X71 75 PELV 9
Interface, E67 77 PELV power supply unit 27
Interface, EtherCAT X65 52 Performance level 82
Interfaces, DeviceNet 66 Peripheral cables 13
Interfaces, discrete 32 PFH values 82
Interfaces, overview 13 PL 82
Internal power supply X33 64 Planning 31
Introduction 7 Power cable 13
Power supply for Fast Measurement 64
K Power supply, external 42
KCB 8 Product description 13
KEB 8 PROFIBUS interface X15A 69
KLI 8 PROFIBUS interface X15B 69
KLI interface on CSP 73 PROFIBUS master X61 70
KLI interfaces 21, 72 PROFIBUS master/slave 62
KONI 8 PROFIBUS, interfaces 69
KPC 8 PROFINET SYNC, X63 50
KPP 8 Purpose 11
KR C4 13
KR C4 extended 13 Q
KR C4 extended CK 13 QBS 9
KR C4 midsize 13
KR C4 midsize CK 13 R
KR C4 CK 13 RDC 9
KRL 8 RDC cool 9
KSB 8 Reference switch, X42 40
KSI 9 RoboTeam interface 75
KSI interfaces 21 RTS 9
KSP 9
KSS 9 S
KUKA Customer Support 87 Safe Robot Technology 32
KUKA smartPAD cable 13 Safely isolated 27
SafeOperation X13 33
L SafeOperation, X42 40
Load voltage contactor, checking 46 SafeRangeMonitoring, X13 35
load voltage US1 45 SafeRobot, X13 32
Load voltage US1, X11 43 SafeSingleBrake, X13 36
Load voltage US1, X56 44 Safety 29
Load voltage US1/US2 81 Safety instructions 7
Load voltage US2, X11 43 Safety Interface Board 25
Load voltage US2, X56 44 Safety Interface Board Extended 27
Load voltages 43 Safety options, interface 32
Lower connection panel 14 Safety options, interfaces 32
SATA connections 9
M Service, KUKA Roboter GmbH 87
Maintenance 85 SG FC 9
Maintenance, SIB Extended 85 SIB 9, 25
Manipulator 9 SIB description 25
Motor cables 13 SIB Extended 27
SIB functions 25
N SIB inputs 28
NA 9 SIB outputs 27
SIB, safe input 38
O SIB, safe output 39
Outputs, 16-channel 59 Signal “Peri enabled” 80
outputs, 16-channel 60 SION 9

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 Index

SOP 9 X67.2, VARAN 65

SPS (PLC) 9
SRM 9
SSB 9
Support request 87
Switch overview 21
Switch, external power supply 42

T
Target group 11
Technical data 27
Terms used 8
Test output A 33, 35, 36, 41, 77, 79
Test output B 33, 35, 36, 41, 77, 79
Trademarks 7
Training 11

U
US1 9
US2 9
US2 function, checking 46
USB 9

V
VARAN slave bus coupler 63
VARAN slave, external power supply 42

W
Warnings 7

X
X11, external power supply 42
X11, load voltages US1 and US2 43
X13, contact diagram 32
X13, SafeRangeMonitoring 35
X13, SafeRobot 32
X13, SafeSingleBrake 36
X14A 24V PWR IN NA 50
X14A 27V PWR IN 49
X14A 27V PWR IN NA 49
X14A, connector pin allocation 49, 50
X14B 24V PWR NA US1/US2 48
X14B 27V PWR NA US1/US2 47
X14B 27V PWR US1 47
X14B 27V PWR US1/US2 46
X14B connector pin allocation 47, 48, 49
X17, KLI interfaces 74, 75
X31, X32 floating contacts 71
X31, X32 interface 71
X33 63
X53, “Drives ready” lamp 40
X55, external power supply 42
X56 44
X61 70
X63, PROFINET SYNC 50
X65 52
X66, Ethernet interface 72
X67, KLI interfaces 73
X67.1, EtherCAT bridge 53
X67.1, VARAN 65
X67.2, EtherCAT bridge 53

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