CONTROL CABINET

KR C1 A

Connection / Start--up

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e Copyright

KUKA Roboter GmbH

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

PD Interleaf
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Contents
1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring the input/output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic system start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The technology-- specific organization program CELL.SRC . . . . . . . . . .

The P00 (AUTOMATIC EXTERNAL) module . . . . . . . . . . . . . . . . . . . . . . . .

10

5.1
5.1.1
5.1.2
5.1.3

The EXT_PGNO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Request of a program number from the host computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication of receipt of a program number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10
10
10
11

5.2

The EXT_ERR function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.1.9
6.1.10

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO_TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO_LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO_FBIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO_PARITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO_VALID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXT_START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOVE_ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONF_MESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVES_ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVES_OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13
13
13
13
14
14
14
15
15
15

6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.2.9
6.2.10
6.2.11

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPMESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO_REQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPL_RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERI_RDY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM_STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USER_SAF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T1, T2, AUT, EXTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON_PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRO_ACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IN_HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERR_TO_PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16
16
16
16
16
16
16
16
17
18
18
18

6.3
6.3.1
6.3.2

Other variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PGNO_ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
19
19

Signal diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

7.1

Automatic system start and normal operation with program number

acknowledgement by means of PGNO_VALID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

7.2

Automatic system start and normal operation with program number

acknowledgement by means of $EXT_START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

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Connection / Start--up
7.3

Restart after dynamic braking (operator safety and restart) . . . . . . . . . . . . . . . . . . . . . . . . . .

22

7.4

Restart after path--maintaining EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

7.5

Restart after motion enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

7.6

Restart after user STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Restart after passive stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

9.1

Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

10

Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

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Connection / Start--up

Connection
(Connecting cables -- robot, ground conductor, power supply connection, peripheral
cables)
The controller must be connected in accordance with the diagram in Fig. 2. The connection
procedure can be divided into:
G

Connection of connecting cables to robot

Connection of connecting cables to periphery

Robot equipotential bonding

Power supply connection

The following basic rules must be observed when connecting the controller:
Before the work is started, the main switch must be turned to OFF and locked.

Main switch

G Cables not belonging to the controller must not be installed inside the control cabinet.
G The ground conductors must not be looped or connected to an intermediate terminal.
G All cables must be protected against mechanical or any other type of stress (e.g. installed
on racks in the cable duct).
Permissible cable lengths
The designations and standard and optional lengths of the connecting cables may be noted
from the table.
Length designation

Standard lengths
in m

Optional lengths
in m

Motor cable
(motor/brake
monitoring)

L1

15 / 25

Signal cable
(control cable)

L1

15 / 25

KCP cable

L2

10

Cable designation

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Connector panel / Peripheral interfaces

Connector panel / Peripheral interfaces

For the purpose of operating the robot in a stand--alone mode or with an external controller,
or for controlling peripheral equipment through the robot system, the connectors X20, X7,
X21, X19, X1 and X01 are provided. These connectors have the following functions:
G

X20: Motor connector, axes 1/3/4

X7:

X21: Data connector

X11: Periphery data connector (optional)

X13: (optional)

X19: KCP connection

X1:

X01: Service socket (optional)

X7.1 Motor connector, external axis 7 (optional)

X7.2 Motor connector, external axis 8 (optional)

X8.1 Resolver connector, external axis 7 (optional)

X8.2 Resolver connector, external axis 8 (optional)

Motor connector, axes 2/5/6

Power supply connection HAN 6

X11

X13 (optional)

X7

Optional

X20

Optional

The pin assignment of the CAN bus and Ethernet interfaces is also described in this documentation.

X01
X1
X21

X19

PE

X7.1/X8.1
X7.2/X8.2

Fig. 1 Connector panel

All contactor, relay and valve coils that are connected to the robot controller must be
equipped with appropriate suppressor diodes.

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Connection / Start--up

KUKA Control Panel

Connector panel,
control cabinet KR C1 A
12

1
2
3
4
5
6
7
8
9
10
11
12

10
11

Control Panel

Data cable

Motor cable, axes 1/3/4

Motor cable, axes 2/5/6

1 2 3

Connector panel, robot

X30/X30.2

X31

Motor connector, axes 1; 3; 4 (X20)

Motor connector, axes 2; 5; 6 (X7)
Optional
Peripheral interface (X11, optional)
Optional
Optional (X13)
Data cable (X21)
KCP connection (X19)
Han 6 HsB power supply connection (X1)
Motor connector X7.1, resolver connector X8.1 (optional)
Motor connector X7.2, resolver connector X8.2 (optional)
Service socket (optional)
Fig. 2 Connection of connecting cables
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Connector pin allocation

3.1

Explanation of symbols

3.2

electronic input, logic 1

=
=
=

relay coil 18 V --- 30 V

Connector pin allocation

electronic output

15 V --- 30 V (approx. 6.5 mA at 24 V)

= 15V --- 30V DC

load current for 2 A output min.: 0.02 A

max.: 2 A

= relay contact max. 500 mA / 30 V

low active signal

make contact

contact max. 500 mA / 30 V

= relay
break contact

power protection 500 mA

Interface signals X11

Interface signal

Pin

Description

Remarks

24 V control voltage

37
1 / 19

0 V internal
+24 V internal,
max. 500 mA

For supplying the safety

circuit with internal power

Emergency Stop
channels 1 and 2

2/3
20 / 21

Floating contacts of the

Emergency Stop button
on the KCP, 2--channel.

These contacts must be

externally linked to the
Emergency Stop relays.

Emergency Stop relay

channels 1 and 2

4
22

Emergency Stop input,

2--channel

CAUTION
Jumpering the two channels with one another is
not permitted.

Emergency Stop relay

0V

40

0 V connection of the
Emergency Stop relays
for connection to the internal or external supply
voltage.

Ext. enabling channels

1 and 2

5/6
23 / 24

For connecting an
external enabling switch
to 2 floating contacts.

Safeguard channels 1
and 2

7/8
25 / 26

For the 2--channel conCAUTION

nection of the interlock of Jumpering the two chanisolating safeguards.
nels with one another is
not permitted.

Ext. drives OFF

41 / 42

A floating contact (break

contact) can be connected to this input. The
drives are switched off
when the contact is
opened.

If no supplementary
switch is connected, pins
5 and 6 as well as 23
and 24 must be
jumpered.
CAUTION
Jumpering the two
channels with one
another is not permitted.

If this input is not used,

pins 41 / 42 must be
jumpered.

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Connection / Start--up
Ext. drives ON

43 / 44

For connecting a floating Signal must not be percontact. Pulse 200 ms manently active.
switches the drives on.

Emergency Stop contact channels 1 and 2

9 / 10
27 / 28

Floating contact of the

Emergency Stop relays.

Contacts are closed if

Emergency Stop is
released.

Safety circuit channels

1 and 2

11 / 12
29 / 30

Floating contacts of the

safety circuit

Is closed if the safeguard input is closed

during automatic operation or if the enabling
switch is pressed in the
Test mode.

Test and Automatic

mode groups

48 / 46
48 / 47

Floating contacts of the

operating mode relays.

Test contact is closed if

Test1 or Test2 is selected on the KCP. Automatic contact is closed if
Automatic or External is
selected.

Rapid gaging
channels 1 to 4

13 / 14
/ 31 /
32 / 49

Inputs are read by the

DSEAT at the 125 ms
clock rate.

When a 0/1 or 1/0 edge

is detected, the actual
axis values are stored by
the software.

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

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3.3

Connector pin allocation (continued)

Emergency Stop circuit

The following examples show how the robot Emergency Stop circuit can be linked to other
robots or with the periphery.
X11
0V internal

37

24V internal

1
19
Emergency Stop channel 1 I

Emergency Stop channel 1 O

Emergency Stop channel 2 I

20

Emergency Stop channel 2 O

21

Em. Stop relay channel 1

Em. Stop relay channel 2

22

Emergency Stop realy 0V

40

Emergency Stop circuit for one robot without periphery

X11
0V internal

37

24V internal

1
19
Emergency Stop channel 1 I
Emergency Stop channel 1 O

2
3

Emergency Stop channel 2 I

20

Emergency Stop channel 2 O

21

Em. Stop relay channel 1

Em. Stop relay channel 2

22

Emergency Stop relay 0V

40

0V internal

37

24V internal

1
19
Emergency Stop channel 1 I

Emergency Stop channel 1 O

Emergency Stop channel 2 I

20

Emergency Stop channel 2 O

21

Em. Stop relay channel 1

Em. Stop relay channel 2

22

Emergency Stop relay 0V

40

Emergency Stop circuit for two robots without periphery

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Connection / Start--up

X11
0V internal

37

24V internal

1
19
Emergency Stop channel 1 I

Emergency Stop channel1 O

Emergency Stop channel 2 I

20

Emergency Stop channel 2 O

21

Em. Stop relay channel 1

Em. Stop relay channel 2

22

Emergency Stop relay 0V

40

Em. Stop button

periphery
Em. Stop-switching
device

Em. Stop
periphery

Emergency Stop circuit for one robot with periphery

X11
0V internal

37

24V internal

1
19
Emergency Stop channel 1 I

Emergency Stop channel 1 O

Emergency Stop channel 2 I

20

Emergency Stop channel 2 O

21

Em. Stop relay channel 1

Em. Stop relay channel 2

22

Emergency Stop relay 0V

40

24V external
0V external
Em. Stop button
periphery
Em. Stop
switching
device

Em. Stop
periphery

Emergency Stop circuit with external voltage supply and with periphery

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3.4

Connector pin allocation (continued)

Supply connection X1, service socket X01

X1

Incoming supply
3x400V 50/60Hz 25A

L1

L2

only with transformer:

L3

3x380V 50/60Hz 25A

3x440V 50/60Hz 25A

PE

PE

3x415V 50/60Hz 25A

3x480V 50/60Hz 25A

3x500V 50/60Hz 25A

* N--conductor is only required for optional

service socket on 400V mains

Fig. 3 Supply connection X1

X01
L1

Service socket

(Standard version with PEN conductor in

the mains!)

PE

Supply voltage dependent on the mains

used; max. load capacity 6A

Fig. 4 Service socket X01 (optional)

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Connection / Start--up

3.5

Motor connector X20, axes 1, 3 and 4

X20
a1
a4
a6
a3
a5

b1
b4
b6
b3
b5

c1
c4
c6
c3
c5

d1
d4
d4

e1
e4
e6

f1
f4
f6

PE
PE

Motor A1 U1
Motor A1 V1
Motor A1 W1
Brake A1 26V
Brake A1 0V

Motor A3 U1
Motor A3 V1
Motor A3 W1
Brake A3 26V
Brake A3 0V

Motor A4 U
Motor A4 V
Motor A4 W
Brake A4 26V
Brake A4 0V

Motor A1 U2
Motor A1 V2
Motor A1 W2

Motor A3 U2
Motor A3 V2
Motor A3 W2

n. c.
n. c.
n. c.

Ground conductor 2.5 mm2

Ground conductor 6.0 mm2

Fig. 5 Motor connector X20

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3.6

Connector pin allocation (continued)

Motor connector X7, axes 2, 5 and 6

X7
a1
a4
a6
a3
a5

b1
b4
b6
b3
b5

c1
c4
c6
c3
c5

d1
d4
d4

PE
PE

Motor A2 U1
Motor A2 V1
Motor A2 W1
Brake A2 26V
Brake A2 0V

Motor A5 U
Motor A5 V
Motor A5W
Brake A5 26V
Brake A5 0V

Motor A6 U
Motor A6 V
Motor A6 W
Brake A6 26V
Brake A6 0V

Motor A2 U2
Motor A2 V2
Motor A2 W2

Ground conductor 2.5 mm2

Ground conductor 6.0 mm2

Fig. 6 Motor connector X7

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Connection / Start--up

3.7

Peripheral connector X11 (optional)

0V internal
+24V internal

X11
37
600 mA

1
19

EM. STOP
KCP

600 mA

2
3

600 mA

20
21
4
22
40
5
6
23

Safety circuit

24
7
8
25
26
41
Drives ON
circuit

42
43
44
600 mA

9
10

600 mA

27
28

600 mA

11
12

600 mA

29
30
46
47

600 mA

48

0V internal
+24V internal
+24V internal
EM. STOP channel 1 l
EM. STOP channel 1 O
EM. STOP channel 2 l
EM. STOP channel 2 O
EM. STOP relay channel 1
EM. STOP relay channel 2
EM. STOP relay 0V
Ext. enabling channel 1 l
Ext. enabling channel 1 O
Ext. enabling channel 2 l
Ext. enabling channel 2 O
Safeguard channel 1 l
Safeguard channel 1 O
Safeguard channel 2 l
Safeguard channel 2 O
Ext. drives OFF I
Ext. drives OFF O
Ext. drives ON I
Ext. drives ON O
EM. STOP contact channel 1 l
EM: STOP contact channel 1 O
EM. STOP contact channel 2 l
EM. STOP contact channel 2 O
Safety circuit channel 1 l
Safety circuit channel 1 O
Safety circuit channel 2 l
Safety circuit channel 2 O
Test mode group
AUTO mode group
COM mode group

Fig. 7 Peripheral connector X11, part 1

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Connector pin allocation (continued)

0V internal
+24V internal

X11
Servo module

13
14
31
32
49
15

Cross connections to
optional connectors X12, X13

16
17
18
33
34
35
36
52
53
54
38
39
45
50
51
91
56
74
92
73
55

Rapid gaging channel 1

Rapid gaging channel 2
Rapid gaging channel 3
Rapid gaging channel 4
Rapid gaging 0V
Cross connection 1
Cross connection 2
Cross connection 3
Cross connection 4
Cross connection 5
Cross connection 6
Cross connection 7
Cross connection 8
Cross connection 9
Cross connection 10
Cross connection 11
n. c.
n. c.
n. c.
n. c.
n. c.
Output 17 (2A)
Output 18 (2A)
Output 19 (2A)
Output 20 (2A)
0V output 17--20
+24V output 17--20

Fig. 8 Peripheral connector X11, part 2

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Connection / Start--up
0V internal
+24V internal

X11
93
58
76
94
59
77
95
60
75
57
61
79
97
62
80
98
63
81
96
78

Output 1 (100mA)
Output 2 (100mA)
Output 3 (100mA)
Output 4 (100mA)
Output 5 (100mA)
Output 6 (100mA)
Output 7 (100mA)
Output 8 (100mA)
0V output 1--8
+24V output 1--8
Output 9 (100mA)
Output 10 (100mA)
Output 11 (100mA)
Output 12 (100mA)
Output 13 (100mA)
Output 14 (100mA)
Output 15 (100mA)
Output 16 (100mA)
0V output 9--16
+24V output 9--16

Fig. 9 Peripheral connector X11, part 3

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Connector pin allocation (continued)

0V internal
+24V internal

X11
64
82
100
65
83
101
66
84
99
67
85
103
68
86
104
69
87
102

Cross connection to
optional connectors X12, X13

70
71
72
88
89
90
106
107
108
105

Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
0V input 1--8
Input 9
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Input 16
0V input 9--16
Cross connection 12
Cross connection 13
Cross connection 14
Cross connection 15
Cross connection 16
Cross connection 17
Cross connection 18
Cross connection 19
Cross connection 20
n. c.

Fig. 10 Peripheral connector X11, part 4

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Connection / Start--up

3.8

Data cable connector X21

X21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

R1
R2
Shield
n. c.
S1
S3
Shield
n. c.
S2
S4
Shield
n. c.
EMT Signal
n. c.
n. c.
Shield
MT1
MT2
R1
R2
Shield
n. c.
S1
S3
Shield
n. c.
S2
S4
Shield
n. c.
EMT Signal

Fig. 11 Data cable connector X21 / part 1

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Connector pin allocation (continued)

X21
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62

n. c.
n. c.
Shield
MT1
MT2
R1
R2
Shield
n. c.
S1
S3
Shield
n. c.
S2
S4
Shield
n. c.
Shield
n. c.
n. c.
Shield
MT1
MT2
R1
R2
Shield
n. c.
S1
S3
Shield
n. c.

Fig. 12 Data cable connector X21 / part 2

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Connection / Start--up

X21
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93

S2
S4
Shield
n. c.
EMT Signal
n. c.
n. c
Shield
MT1
MT2
R1
R2
Shield
n. c.
S1
S3
Shield
n. c.
S2
S4
Shield
n. c.
EMT Signal
n. c.
n. c.
Shield
MT1
MT2
R1
R2
Shield

Fig. 13 Data cable connector X21 / part 3

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Connector pin allocation (continued)

X21
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
PE

n. c.
S1
S3
Shield
n. c.
S2
S4
Shield
n. c.
Shield
n. c.
n. c.
Shield
MT1
MT2
Ground

Fig. 14 Data cable connector X21 / part 4

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Connection / Start--up

3.9

KCP connector X19

X19
1
3

2
4

1
3
2
4

Display screen KCP +

Display screen KCP --

CAN bus +
CAN bus --

TxD +
TxD -RxD +
RxD --

EM. STOP 2 OUT

EM. STOP 2 IN

EM. STOP 1 OUT

EM. STOP 1 IN

10

0V

11

24V

not assigned

Drives ON

Drives OFF

Mode AUTO

Mode TEST

Mode (GND)

Enabling channel 2

7
9

Enabling channel 1
Enabling (GND)

Fig. 15 KCP connector X19

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3.10

Connector pin allocation (continued)

Jumpers for stand--alone operation X11

0V internal
+24V internal

X11
37
1
EM. STOP
KCP

19
2
3
20
21
4
22
40
5
6
23

7
8
25
26

Safeguard

Safety circuit

24

Drives ON
circuit

41
42
43
44
9
10
27
28
11
12
29
30
46
47
48

Fig. 16 Jumpers for stand--alone operation X11

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Connection / Start--up

Putting the control cabinet into operation

4.1

Operator control elements on the KUKA Control Panel

The KUKA Control Panel (KCP) is used for teaching and operating the robot controller
KR C1A. The keyboard and status data are transferred via a standard CAN bus to the PC.
The display information is transferred serially via a separate high--speed interface.
The KCP features an 8--inch full--graphics color display (VGA resolution 640x480), a membrane keyboard, a 6D mouse and the control elements EMERGENCY STOP, Drives ON/
OFF, mode selector switch and enabling switches.
It is also possible to connect an MF II keyboard to the KCP via a DIN connector on the back
of the KCP.
The Ethernet connection allows data to be archived on a PC.

.
Mode selector
switch

Drives ON/OFF

EMERGENCY
STOP
6D mouse

Display

Membrane
keyboard

Front view of KCP

Cover of interface for MF II keyboard
and Ethernet connection

Enabling
switches

Enabling
switches

Rear view of KCP

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Putting the control cabinet into operation (continued)

The Windows environment guides the user through all the necessary procedures:
G

Start--up of the robot controller

Programming

Program test and correction

Program control (start, stop)

Visualization and diagnostics during production

The following displays are possible on the screen:

4.2

Application programs, program status

Interrupt, override

Program display, motion display

Actual value display, following error display

Online correction, mastering display

Robot position, traversing mode

Interface signals, messages

Logbook

Help display

Switching on the control cabinet

Before switching on the controller, make sure that nobody is present within the
working range of the robot. The mushroom--head EMERGENCY STOP button on the
KCP should be pressed.
After you have correctly installed and connected your robot system, you can start it up for
the first time.
Turn on the main switch of your control cabinet. The computer integrated into the control cabinet begins to load the programs and data required for operation from the hard disk. You can
follow the run--up phase of the controller on the KCP display. The run--up phase is concluded
after approximately 3 minutes and the main menu of the KR C1 A controller is displayed.
As the EMERGENCY STOP button is pressed at this stage (and the EMERGENCY STOP
circuits of the periphery may not have been wired up yet), the robot cannot yet be moved.
Appropriate messages are displayed on the KCP to inform you of this.

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Connection / Start--up
To prepare your system for production, you must wire up the EMERGENCY STOP circuits,
master the robot axes and calibrate the tool that is fitted. The relevant information can be
found in the following documentation:
Operating Handbook, Control Cabinet (this documentation)
Wiring up the EMERGENCY STOP circuits
-- [Connection/Start--up]
Operating Handbook, Start--up
Mastering the robot axes
-- [Robot Mastering/Unmastering]
Calibrating the tool
-- [Tool Calibration]

4.3

Online documentation
If your documentation is available on CD--ROM, you can have this displayed on the KCP or
on a suitably equipped PC and printed out.
The booklet (Safety and Installation Instructions) accompanying the CD--ROM explains how
to access the documentation on your CD--ROM.

4.4

Switching off the control cabinet

To switch off, turn the main switch on the control cabinet to the OFF position. Shutdown
of the control computer as with Windows 95 is not necessary.

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Index

Symbols
#PGNO_ACKN, 10
#PGNO_FAULT, 11
$CONFIG.DAT, 26
$EXT_START, 7, 21
$EXT_START$IN[ ], 27
$I_O_ACTCONF, 7
$I_O_ACTCONF $OUT[ ], 27
$MACHINE.DAT, 27
$POS_RET, 14, 17
$PRO_I_O[], 7
$STOPMESS $OUT[ ], 27

M
Motion enable, 24
MOVE_ENABLE, 14

N
NEAR_POSRET, 17

O
ON_PATH, 17
Operator safety, 22

P
ALARM_STOP, 16
APPL_RUN, 16
APPL_RUN , 26
AUT, 16

P00 module, 10
PERI_RDY, 16
PGNO, 19, 26
PGNO_ERROR, 19, 26
PGNO_FBIT, 13, 26
PGNO_LENGTH, 13, 26
PGNO_PARITY, 13, 26
PGNO_REQ, 10, 16, 26
PGNO_TYPE, 13, 26

C
CELL.SRC, 7, 19
CONF_MESS, 15
Configuration example, 27

PGNO_VALID, 14, 20
PRO_ACT, 18
Program number acknowledgement, 20

D
DRIVES_OFF, 15
DRIVES_ON, 15
Dynamic braking, 22

R
Restart, 22

E
EMERGENCY STOP, 23
ERR_FILE, 12
ERR_TO_PLC, 18
EXT_ERR, 12
EXT_PGNO, 10, 11
EXT_PGNO.SRC, 19
EXT_START, 14
EXTERN, 16

I
I/O, 5
I/O interface, 7
IN_HOME, 18

S
SPS.SUB, 7
STOPMESS, 16

T
T1, 16
T2, 16

U
User STOP, 25
USER_SAF, 16

Index -- i