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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.1 PGNO_TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.2 PGNO_LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.3 PGNO_FBIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.4 PGNO_PARITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1.5 PGNO_VALID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1.6 EXT_START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1.7 MOVE_ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1.8 CONF_MESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.9 DRIVES_ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.10 DRIVES_OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.1 STOPMESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.2 PGNO_REQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.3 APPL_RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.4 PERI_RDY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.5 ALARM_STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.6 USER_SAF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.7 T1, T2, AUT, EXTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2.8 ON_PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2.9 PRO_ACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2.10 IN_HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2.11 ERR_TO_PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Other variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3.1 PGNO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3.2 PGNO_ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 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
9 Configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1 Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Connection / Start--up
1 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
G Connection of connecting cables to periphery
G Robot equipotential bonding
G 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
1
0
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).
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2 Connector panel / Peripheral interfaces
X01
X13 (optional)
Optional
Optional
X1
X7.1/X8.1
X20 X7 X11 X21 X19
PE X7.2/X8.2
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
Connector panel,
control cabinet KR C1 A
12
1 2 3 4 5 6 7 8 9
10
11
Control Panel
Motor cable, axes 1/3/4
Motor cable, axes 2/5/6
Data cable
X30/X30.2 X31
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3 Connector pin allocation
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Connection / Start--up
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 Connector pin allocation (continued)
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
X11
0V internal 37
24V internal 1
19
0V internal 37
24V internal 1
19
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Connection / Start--up
X11
0V internal 37
24V internal 1
X11
24V external
0V internal 37
0V external
24V internal 1
Em. Stop button
19
periphery
Emergency Stop channel 1 I 2
Em. Stop
Emergency Stop channel 1 O 3 switching
device
Emergency Stop channel 2 I 20
Emergency Stop circuit with external voltage supply and with periphery
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3 Connector pin allocation (continued)
X1 Incoming supply
3x400V 50/60Hz 25A
1 L1
3x415V 50/60Hz 25A
2 L2 only with transformer:
3 L3 3x380V 50/60Hz 25A
X01
L1 Service socket
N (Standard version with PEN conductor in
the mains!)
Supply voltage dependent on the mains
PE used; max. load capacity 6A
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Connection / Start--up
X20
a1
Motor A1 U1
a4
Motor A1 V1
a6
Motor A1 W1
a3
Brake A1 26V
a5
Brake A1 0V
b1
Motor A3 U1
b4
Motor A3 V1
b6
Motor A3 W1
b3
Brake A3 26V
b5
Brake A3 0V
c1
Motor A4 U
c4
Motor A4 V
c6
Motor A4 W
c3
Brake A4 26V
c5
Brake A4 0V
d1
Motor A1 U2
d4
Motor A1 V2
d4
Motor A1 W2
e1
Motor A3 U2
e4
Motor A3 V2
e6
Motor A3 W2
f1
n. c.
f4
n. c.
f6
n. c.
PE
Ground conductor 2.5 mm2
PE
Ground conductor 6.0 mm2
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3 Connector pin allocation (continued)
X7
a1
Motor A2 U1
a4
Motor A2 V1
a6
Motor A2 W1
a3
Brake A2 26V
a5
Brake A2 0V
b1
Motor A5 U
b4
Motor A5 V
b6
Motor A5W
b3
Brake A5 26V
b5
Brake A5 0V
c1
Motor A6 U
c4
Motor A6 V
c6
Motor A6 W
c3
Brake A6 26V
c5
Brake A6 0V
d1
Motor A2 U2
d4
Motor A2 V2
d4
Motor A2 W2
PE
Ground conductor 2.5 mm2
PE
Ground conductor 6.0 mm2
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Connection / Start--up
X11
37
0V internal
600 mA 1
+24V internal
19
+24V internal
EM. STOP
KCP 600 mA 2
EM. STOP channel 1 l
3
EM. STOP channel 1 O
600 mA 20
EM. STOP channel 2 l
21
EM. STOP channel 2 O
4
EM. STOP relay channel 1
22
EM. STOP relay channel 2
40
EM. STOP relay 0V
5
Ext. enabling channel 1 l
6
Ext. enabling channel 1 O
23
Ext. enabling channel 2 l
24
Ext. enabling channel 2 O
Safety circuit
7
Safeguard channel 1 l
8
Safeguard channel 1 O
25
Safeguard channel 2 l
26
Safeguard channel 2 O
41
Ext. drives OFF I
42
Ext. drives OFF O
Drives ON
43
circuit
Ext. drives ON I
44
Ext. drives ON O
600 mA 9
EM. STOP contact channel 1 l
10
EM: STOP contact channel 1 O
600 mA 27
EM. STOP contact channel 2 l
28
EM. STOP contact channel 2 O
600 mA 11
Safety circuit channel 1 l
12
Safety circuit channel 1 O
600 mA 29
Safety circuit channel 2 l
30
Safety circuit channel 2 O
46
Test mode group
47
AUTO mode group
600 mA 48
COM mode group
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3 Connector pin allocation (continued)
0V internal
+24V internal
X11
13
Rapid gaging channel 1
14
Servo module
Rapid gaging channel 2
31
Rapid gaging channel 3
32
Rapid gaging channel 4
49
Rapid gaging 0V
15
Cross connection 1
16
Cross connection 2
17
optional connectors X12, X13
Cross connection 3
18
Cross connection 4
Cross connections to
33
Cross connection 5
34
Cross connection 6
35
Cross connection 7
36
Cross connection 8
52
Cross connection 9
53
Cross connection 10
54
Cross connection 11
38
n. c.
39
n. c.
45
n. c.
50
n. c.
51
n. c.
91
Output 17 (2A)
56
Output 18 (2A)
74
Output 19 (2A)
92
Output 20 (2A)
73
0V output 17--20
55
+24V output 17--20
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Connection / Start--up
0V internal
+24V internal
X11
93
Output 1 (100mA)
58
Output 2 (100mA)
76
Output 3 (100mA)
94
Output 4 (100mA)
59
Output 5 (100mA)
77
Output 6 (100mA)
95
Output 7 (100mA)
60
Output 8 (100mA)
75
0V output 1--8
57
+24V output 1--8
61
Output 9 (100mA)
79
Output 10 (100mA)
97
Output 11 (100mA)
62
Output 12 (100mA)
80
Output 13 (100mA)
98
Output 14 (100mA)
63
Output 15 (100mA)
81
Output 16 (100mA)
96
0V output 9--16
78
+24V output 9--16
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3 Connector pin allocation (continued)
0V internal
+24V internal
X11
64
Input 1
82
Input 2
100
Input 3
65
Input 4
83
Input 5
101
Input 6
66
Input 7
84
Input 8
99
0V input 1--8
67
Input 9
85
Input 10
103
Input 11
68
Input 12
86
Input 13
104
Input 14
69
Input 15
87
Input 16
102
0V input 9--16
70
Cross connection 12
71
Cross connection 13
optional connectors X12, X13
72
Cross connection 14
88
Cross connection to
Cross connection 15
89
Cross connection 16
90
Cross connection 17
106 Cross connection 18
107
Cross connection 19
108 Cross connection 20
105
n. c.
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Connection / Start--up
X21
1
R1
2
R2
3
Shield
4
n. c.
5
S1
6
S3
7
Shield
8
n. c.
9
S2
10
S4
11
Shield
12
n. c.
13
EMT Signal
14
n. c.
15
n. c.
16
Shield
17
MT1
18
MT2
19
R1
20
R2
21
Shield
22
n. c.
23
S1
24
S3
25
Shield
26
n. c.
27
S2
28
S4
29
Shield
30
n. c.
31
EMT Signal
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3 Connector pin allocation (continued)
X21
32
n. c.
33
n. c.
34
Shield
35
MT1
36
MT2
37
R1
38
R2
39
Shield
40
n. c.
41
S1
42
S3
43
Shield
44
n. c.
45
S2
46
S4
47
Shield
48
n. c.
49
Shield
50
n. c.
51
n. c.
52
Shield
53
MT1
54
MT2
55
R1
56
R2
57
Shield
58
n. c.
59
S1
60
S3
61
Shield
62
n. c.
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Connection / Start--up
X21
63
S2
64
S4
65
Shield
66
n. c.
67
EMT Signal
68
n. c.
69
n. c
70
Shield
71
MT1
72
MT2
73
R1
74
R2
75
Shield
76
n. c.
77
S1
78
S3
79
Shield
80
n. c.
81
S2
82
S4
83
Shield
84
n. c.
85
EMT Signal
86
n. c.
87
n. c.
88
Shield
89
MT1
90
MT2
91
R1
92
R2
93
Shield
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3 Connector pin allocation (continued)
X21
94
n. c.
95
S1
96
S3
97
Shield
98
n. c.
99
S2
100
S4
101
Shield
102
n. c.
103
Shield
104
n. c.
105
n. c.
106
Shield
107
MT1
108
MT2
PE
Ground
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Connection / Start--up
X19
1
Display screen KCP +
3
Display screen KCP --
2
CAN bus +
4
CAN bus --
1
TxD +
3
TxD --
2
RxD +
4
RxD --
3
EM. STOP 2 OUT
4
EM. STOP 2 IN
1
EM. STOP 1 OUT
2
EM. STOP 1 IN
10
0V
11
24V
1
not assigned
2
Drives ON
3
Drives OFF
4
Mode AUTO
5
Mode TEST
6
Mode (GND)
8
Enabling channel 2
7
Enabling channel 1
9
Enabling (GND)
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3 Connector pin allocation (continued)
0V internal
+24V internal
X11
37
19
EM. STOP
KCP 2
20
21
22
40
23
24
Safety circuit
Safeguard
25
26
41
42
Drives ON
43
circuit
44
10
27
28
11
12
29
30
46
47
48
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Connection / Start--up
6D mouse
Display
Membrane
keyboard
Enabling Enabling
switches switches
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4 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
G Programming
G Program test and correction
G Program control (start, stop)
G Visualization and diagnostics during production
The following displays are possible on the screen:
G Application programs, program status
G Interrupt, override
G Program display, motion display
G Actual value display, following error display
G Online correction, mastering display
G Robot position, traversing mode
G Interface signals, messages
G Logbook
G Help display
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 cabi-
net 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]
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Index
Symbols M
#PGNO_ACKN, 10 Motion enable, 24
#PGNO_FAULT, 11 MOVE_ENABLE, 14
$CONFIG.DAT, 26
$EXT_START, 7, 21
$EXT_START$IN[ ], 27
N
$I_O_ACTCONF, 7 NEAR_POSRET, 17
$I_O_ACTCONF $OUT[ ], 27
$MACHINE.DAT, 27
O
$POS_RET, 14, 17
$PRO_I_O[], 7 ON_PATH, 17
$STOPMESS $OUT[ ], 27 Operator safety, 22
A P
ALARM_STOP, 16 P00 module, 10
APPL_RUN, 16 PERI_RDY, 16
APPL_RUN , 26 PGNO, 19, 26
AUT, 16 PGNO_ERROR, 19, 26
PGNO_FBIT, 13, 26
C PGNO_LENGTH, 13, 26
CELL.SRC, 7, 19 PGNO_PARITY, 13, 26
CONF_MESS, 15 PGNO_REQ, 10, 16, 26
Configuration example, 27 PGNO_TYPE, 13, 26
PGNO_VALID, 14, 20
D PRO_ACT, 18
Program number acknowledgement, 20
DRIVES_OFF, 15
DRIVES_ON, 15
Dynamic braking, 22 R
Restart, 22
E
EMERGENCY STOP, 23
S
ERR_FILE, 12
ERR_TO_PLC, 18 SPS.SUB, 7
EXT_ERR, 12 STOPMESS, 16
EXT_PGNO, 10, 11
EXT_PGNO.SRC, 19 T
EXT_START, 14
T1, 16
EXTERN, 16
T2, 16
I
I/O, 5 U
I/O interface, 7 User STOP, 25
IN_HOME, 18 USER_SAF, 16
Index -- i