ROBOT

KR 6, 15, 30, 45, 60, 125, 125 S, 150, 200

Description, Connecting Cables, Robot -- Control Cabinet

Ro/El/01/01 10.98.01 en

1 of 10
e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

Ro/El/01/01 10.98.01 en

2 of 10
Contents

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

2 Cable installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Junction boxes on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Connector panel on control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Configuration of the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Connector pin allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ro/El/01/01 10.98.01 en

3 of 10
Description, Connecting Cables, Robot -- Control Cabinet

Ro/El/01/01 10.98.01 en

4 of 10
 1 General

Valid for all robot types KR ...

except
KR 125 W
KR 125 K
KR 125 L100 K
KR 125 L90 K
KR 150 K
KR 60 P
KR 100 P
KR 100 PA
KR 160 PA

1 General
Connecting cables are all the plug--in cables running between the robot and the control
cabinet (Fig. 1). They have plug--in connections at both ends. The terminal allocation of the
connectors is given in list form (Section 6). In order to avoid the connectors being mixed up,
the ends of each cable are provided with a designation label, which must match the
corresponding connection point on the robot or on the control cabinet. The cable connections
on the robot and control cabinet are shown in Fig. 1.
The connection points for the connecting cables are the junction boxes on the robot (Fig. 2 to
Fig. 4) and the connector panel on the control cabinet (Fig. 5).

The connectors must be inserted carefully to avoid damaging the contacts.

With connecting cables longer than 25 m, an additional ground conductor is required in order
to ensure a low--resistance connection in accordance with DIN EN 60204.
The ground conductor is fastened with cable lugs to threaded bolts.
Before the robot is put into operation, the continuity of the ground conductor
connection between the robot and the control cabinet must be checked by
means of a ground conductor measurement in accordance with
DIN EN 60204--20.2.

Control cabinet Robot

KR C1 Motor cable X30
X20

X21 Data cable X31

Ground conductor 16 mm2

only required for cable lengths > 25 m

Fig. 1 Connecting cables

Ro/El/01/01 10.98.01 en

5 of 10
Description, Connecting Cables, Robot -- Control Cabinet

2 Cable installation
The following points must be observed when laying the cables:
-- Ensure that the bending radius of the cables is not less than the specified value
(for fixed cabling 120 mm).
-- Protect the cables from mechanical loads and stresses.
-- Installation of the cables must be free from tension (no tensile forces on the con-
nectors).
-- Cables must only be layed indoors.
-- Observe the temperature range (fixed cabling) of --10 _C to +70 _C.

Ro/El/01/01 10.98.01 en

6 of 10
 3 Junction boxes on robot

3 Junction boxes on robot

The plug--in connections on the robot are located on the junction boxes on the base frame:
on junction box X01 for the motor cable, on X02 for the data cable. The arrangement of the
junction boxes and the associated connectors for the different robots is indicated in Fig. 2 to
Fig. 4.
If connecting cables longer than 25 m are used, a grounding bolt must be attached to the base
frame for connecting the ground conductor.

X30 X31

X01 X02
Ground conductor
connection

Fig. 2 Junction boxes for KR 30, 45, 60, 125, 150, 200

X30

X01
Ground conductor
connection
X31

X02

Fig. 3 Junction boxes for KR 6, 15

X31 X30
Ground conductor
connection

X02 X01

Fig. 4 Junction boxes for KR 125 S

Ro/El/01/01 10.98.01 en

7 of 10
Description, Connecting Cables, Robot -- Control Cabinet

4 Connector panel on control cabinet

Access to the connector panel (Fig. 5) can be gained after opening the door to the cabinet.
The connected cables are routed under the control cabinet to the rear.

Ground conductor
connection
X20 X21

Fig. 5 Connector panel on control cabinet

Ro/El/01/01 10.98.01 en

8 of 10
 5 Configuration of the connecting cables

5 Configuration of the connecting cables

X20 X30

Rectangular connector Cable diameter approx. 24 mm

with central locking

X20
Contact inserts
(HAN modular): a Motor A1
b Motor A2
c Motor A3
d Motor A4
e
Motor A5
f
Motor A6

Fig. 6 Motor cable

X21 X31

Circular connector, 17--pole Cable diameter approx. 10 mm

Fig. 7 Data cable

PE

Ring--type cable lug,

8.4 mm bore
PE bolt
M8x30 stud
M8 nut mech.galv. DIN 913
VS8 washer
8.4 washer
M8 nut Cable lug
VS8 washer
Ground plate
Robot Thread in base
frame must be
free of paint
and grease
Ground conductor
connection (cross--section)

Fig. 8 Ground conductor

Ro/El/01/01 10.98.01 en

9 of 10
Description, Connecting Cables, Robot -- Control Cabinet

6 Connector pin allocation

Connector X20/X30, Pin no. Assignment Connector X21/X31, Pin no. Assignment
a1 A1 A1/motor U 1 1 not connected
a2 A2 not connected 2 2 GND

1 module
a3 A3 brake + 3 3 24V
a4 A4 A1/motor V 4 4 A1/CLKO
a5 A5 brake -- 5 5 A1/CLKO
a6 A6 A1/motor W 6 6 FSi
b1 B1 A2/motor U 7 7 /FSi
b2 B2 not connected 8 8 Di
b3 B3 brake + 9 9 /Di
b4 B4 A2/motor V 10 10 /FSo
b5 B5 brake -- 11 11 FSo
b6 B6 A2/motor W 12 12 /Do
c1 C1 A3/motor U 13 13 Do
c2 C2 not connected 14 14 /CLKi
c3 C3 brake + 15 15 CLKi
c4 C4 A3/motor V 16 16 not connected
c5 C5 brake -- 17 17 not connected
c6 C6 A3/motor W
d1 D1 A4/motor U
d2 D2 not connected
d3 D3 brake +
d4 D4 A4/motor V
d5 D5 brake --
d6 D6 A4/motor W
e1 E1 A5/motor U
e2 E2 not connected
e3 E3 brake +
e4 E4 A5/motor V
e5 E5 brake --
e6 E6 A5/motor W
f1 F1 A6/motor U
f2 F2 not connected
f3 F3 brake +
f4 F4 A6/motor V
f5 F5 brake --
f6 *) F6 A6/motor W
PE grd. conductor
PE grd. conductor *) all jumpers in X30

Fig. 9 Connector pin allocation X20/X30 Fig. 10 Connector pin allocation X21/X31
1

Ro/El/01/01 10.98.01 en

10 of 10