Kuka KR C4 compact User manual

Controller Option
External Cabling
For KR C4 Robot Controllers
Assembly and Operating Instructions
KUKA Roboter GmbH
Issued: 26.03.2013
Version: MA KR C4 extended extern wiring V1 en (PDF)

External Cabling
2 / 31 Issued: 26.03.2013 Version: MA KR C4 extended extern wiring V1 en (PDF)
© Copyright 2013
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 KR C4 extended externe Verkabelung (PDF) en
Bookstructure: MA KR C4 extended externe Verkabelung V1.1
Version: MA KR C4 extended extern wiring V1 en (PDF)

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Contents
1 Introduction .................................................................................................. 5
1.1 Industrial robot documentation ................................................................................... 5
1.2 Representation of warnings and notes ...................................................................... 5
1.3 Terms used ................................................................................................................ 5
2 Purpose ........................................................................................................ 7
2.1 Target group .............................................................................................................. 7
2.2 Intended use .............................................................................................................. 7
3 Product description ..................................................................................... 9
3.1 Motor box and RDC box connection examples .......................................................... 9
3.1.1 Motor box for 4 axes ............................................................................................. 10
3.1.2 Motor box for 6 axes ............................................................................................. 11
3.1.3 RDC box ............................................................................................................... 11
3.1.4 RDC box (cascadable) .......................................................................................... 12
3.2 Motor cables for multiple motors ................................................................................ 13
3.3 Motor cables for single motors ................................................................................... 13
3.4 Data cable ..................................................................................................................13
3.5 Resolver cable ........................................................................................................... 13
4 Technical data .............................................................................................. 15
4.1 Motor cables for multiple motors ................................................................................ 15
4.1.1 Motor cable for 3 motors ....................................................................................... 15
4.1.2 Motor cable for 4 motors ....................................................................................... 15
4.1.3 Motor cable for 6 motors ....................................................................................... 15
4.1.4 Extensions ............................................................................................................ 15
4.2 Motor cable for single motors ..................................................................................... 16
4.2.1 Extensions ............................................................................................................ 16
4.3 Data cable ..................................................................................................................16
4.3.1 2nd data cable ...................................................................................................... 17
4.3.2 Extensions ............................................................................................................ 17
4.4 Resolver cable ........................................................................................................... 17
4.4.1 Extensions ............................................................................................................ 17
5 Safety ............................................................................................................ 19
6 KUKA Service .............................................................................................. 21
6.1 Requesting support .................................................................................................... 21
6.2 KUKA Customer Support ........................................................................................... 21
Index ............................................................................................................. 29
Contents

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1 Introduction
1Introduction
1.1 Industrial robot documentation
The industrial robot documentation consists of the following parts:
Documentation for the manipulator
Documentation for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to 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.
This warning draws attention to procedures which serve to prevent or remedy
emergencies or malfunctions:
Notes These hints serve to make your work easier or contain references to further
information.
1.3 Terms used
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.
Procedures marked with this warning must be followed
exactly.
Tip to make your work easier or reference to further information.
Term Description
CK Customer-built Kinematics
EDS Electronic Data Storage (memory card)
RDC Resolver Digital Converter
EA External axis (linear unit, Posiflex)

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2 Purpose
2Purpose
2.1 Target group
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
2.2 Intended use
Use The external cabling is valid for the following robot controllers:
KR C4
KR C4 CK
KR C4 midsize
KR C4 midsize CK
KR C4 extended
KR C4 extended CK
KR C4 NA
KR C4 CK NA
KR C4 extended NA
KR C4 extended CK NA
The external cabling for the KR C4 robot controllers must only be used for the
following connections:
Motor cables for multiple motors
Connection of a KR C4 with a manipulator
Connection of a KR C4 with a CK
Connection of a KR C4 with an EA
Connection of a KR C4 with a motor box
Motor cables for single motors
Connection of a motor box with a motor
Connection of a KR C4 with a motor
Data cables
Connection of a KR C4 with an RDC box
Connection of an RDC box with an RDC box
Resolver cables
Connection of an RDC with the resolver of a motor
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
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.

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3 Product description
3 Product description
3.1 Motor box and RDC box connection examples
Description The diagram (>>> Fig. 3-1 ) shows a system with a manipulator with 6 axes
and 8 single axes. The RDC boxes are connected in series (cascade).
Description The diagram (>>> Fig. 3-2 ) shows a system with 16 single axes. The RDC
boxes are connected in series.
Fig. 3-1: Example: 14 axes
1 Connection panel on KR C4 extended robot controller
2 Motor
3 Motor cable for single axis
4 Resolver cable to RDC box
5 Manipulator
6 Motor box for 4 axes
7 RDC box
8 Data cable between the RDC boxes
9 RDC box (cascadable)
10 Data cable between RDC box (cascadable) and robot controller,
X21.1
11 Motor cable between motor box and robot controller
12 Motor cable between manipulator and robot controller
13 Data cable between manipulator and robot controller, X21

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3.1.1 Motor box for 4 axes
Description The motor box is a connection adapter between a motor cable for 4 motors
and 4 motor cables for one motor each. The motor box is connected at the ro-
bot controller with a multiple connector. 4 motor cables can be connected via
single-axis connectors. The motor box is available in the following versions:
with rear wall inlet
with side wall inlet
Fig. 3-2: Example: 16 axes
1 Connection panel on KR C4 extended robot controller
2 Data cable between RDC box (cascadable) and robot controller, X21
3 RDC box (cascadable)
4 Motor box for 4 axes
5 Data cable between the RDC boxes
6 Motor cable between motor box and robot controller
7 RDC box
8 Data cable between RDC box (cascadable) and robot controller,
X21.1
9 Motor cable for single axis
10 Resolver cable to RDC box
11 Motor

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3 Product description
closed
The motor cables of the individual axes must be connected directly to the
HAN modules of the multiple connector. For this, the corresponding holes
for the cable inlets must be drilled in the housing.
Overview
3.1.2 Motor box for 6 axes
Description The motor box is a connection adapter between a motor cable for 6 motors
and 6 motor cables for one motor each. The motor box is connected at the ro-
bot controller with a multiple connector. 6 single-axis motor cables with size 1
circular connectors can be connected. The motor box is available in the follow-
ing versions:
with rear wall inlet
closed
The motor cables of the individual axes must be connected directly to the
HAN modules of the multiple connector. For this, the corresponding holes
for the cable inlets must be drilled in the housing.
Overview
3.1.3 RDC box
Description The Resolver Digital Converter (RDC) is used to detect the motor position da-
ta. 8 resolvers can be connected to the RDC. In addition, the motor tempera-
Fig. 3-3: Motor box for 4 axes
1 Motor box with side wall inlet
2 Motor box with rear wall inlet
3 Motor box (closed)
Fig. 3-4: Motor box for 6 axes
1 Motor box with rear connector outlet
2 Motor box (closed)

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tures are measured and evaluated. For non-volatile data storage, the EDS is
located in the RDC box.
RDC box
3.1.4 RDC box (cascadable)
Description The Resolver Digital Converter (RDC) is used to detect the motor position da-
ta. 8 resolvers can be connected to the RDC. In addition, the motor tempera-
tures are measured and evaluated. For non-volatile data storage, the EDS is
located in the RDC box.
The RDC box is cascadable. 2 RDC boxes per RDC interface (X21 and X21.1)
can be connected in series.
RDC box
(cascadable)
Fig. 3-5: RDC box connections
1 Union for 2 external axis control cables X1 ... X6
2 Bolt for ground conductor connection
3 Data cable X31
4 EMD connection X32
5 Cable inlet for resolver connections X7 and X8
Fig. 3-6
1 EMD connection X32
2 Data cable X31
3 Data cable X21 (cascadable)
4 Cable inlet for resolver connections

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3 Product description
3.2 Motor cables for multiple motors
Description The motor cables for multiple motors are used for the following connections:
KUKA robot and robot controller
CK and robot controller
Motor box and robot controller
3.3 Motor cables for single motors
Description The motor cables for single motors are used for the following connections:
2.5 mm2and 4 mm2between motor box for 6 axes and motor
6 mm2between motor box for 4 axes and motor, or between robot control-
ler and motor
The dimensioning of the cross-section and lengths must be carried out in ac-
cordance with the relevant VDE and EN guidelines and other regulations ap-
plicable to the application and is the responsibility of the system builder.
Extension The motor cable extension for single motors is used for the following connec-
tion:
Motor cable for single motors and motor
3.4 Data cable
Description The data cables are used for the following connections:
Robot controller and RDC box
Robot controller and RDC box (cascadable)
The data cable extensions are used for the following connections:
Data cable and RDC box
Data cable and manipulator
3.5 Resolver cable
Description The resolver cables are used for the following connections:
RDC box and motors
The resolver cable extensions are used for the following connections:
Resolver cable and motors

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4 Technical data
4 Technical data
4.1 Motor cables for multiple motors
4.1.1 Motor cable for 3 motors
4.1.2 Motor cable for 4 motors
4.1.3 Motor cable for 6 motors
4.1.4 Extensions
Interface connector X20.1; X20.2; X20.3
Lengths 7 m, 15 m, 25 m, 35 m, 50 m
Cross-section 3x 10 mm2
Bending radius 100 mm for single bending
Suitable for use in a cable carrier No
Load max. 3x 64 A
Connector type HAN Modular
Outside diameter 27.5 mm, ±0.5 mm
Interface connector X8; X81; X82; X83; X84
Lengths 3 m, 7 m, 10 m, 15 m, 20 m, 25 m,
30 m, 35 m, 50 m
Cross-section 3x 10 mm2, 1x 6 mm2
Bending radius 100 mm for single bending
Suitable for use in a cable carrier No
Load max. 3x 64 A, 1x 40 A
Connector type HAN Modular
Outside diameter 29.9 mm ±0.5 mm
Interface connector X20
Lengths 3 m, 7 m, 10 m, 15 m, 20 m, 25 m,
30 m, 35 m, 50 m
Cross-section 3x 6 mm2, 3x 2.5 mm2
Bending radius 100 mm for single bending
Suitable for use in a cable carrier No
Load max. 3x 40 A, 3x 20 A
Connector type HAN Modular
Outside diameter 30 mm ±0.5 mm
Interface connector X30.1 flexible
Lengths 1.6 m, 2 m, 3 m, 4 m, 5 m, 6 m,
7 m, 8 m, 9 m, 10 m, 11 m, 12 m,
13 m, 14 m, 15 m, 16 m, 17 m,
18 m, 19 m, 20 m, 25 m, 30 m,
35 m
Cross-section 3x 6 mm2, 3x 2.5 mm2

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4.2 Motor cable for single motors
4.2.1 Extensions
Motor connector
type 1 2.5 mm2
4 mm2
Motor connector
type 1.5 6 mm2
4.3 Data cable
Bending radius 250 mm for continuous bending
Suitable for use in a cable carrier Yes
Load max. 3x 40 A, 3x 20 A
Connector type HAN Modular
Outside diameter 30 mm ±0.5 mm
Interface connector X7.1...X7.12
Cross-section 2.5 mm2, 4 mm2, 6 mm2
Bending radius for 2.5 mm 2120 mm for continuous bending
Bending radius for 4 mm 2140 mm for continuous bending
Bending radius for 6 mm 2160 mm for continuous bending
Suitable for use in a cable carrier Yes
Load max. for 2.5 mm 220 A
Load max. for 4 mm 240 A
Load max. for 6 mm 264 A
Connector type H-J1, H-J1.5
Outside diameter for 2.5 mm 210 mm
Outside diameter for 4 mm 212 mm
Outside diameter for 6 mm 216 mm
1.6 m, 2 m, 3 m, 4 m, 5 m, 6 m, 7 m, 8 m, 9 m, 10 m, 11 m, 12 m, 13 m
14 m, 15 m, 16 m, 17 m, 18 m, 19 m, 20 m, 25 m, 30 m, 35 m
1 m, 1.6 m, 2 m, 3 m, 4 m, 5 m, 6 m, 7 m, 8 m, 9 m, 10 m, 11 m, 12 m, 13 m
14 m, 15 m, 16 m, 17 m, 18 m, 19 m, 20 m, 25 m, 30 m, 35 m
1 m, 1.6 m, 2 m, 3 m, 4 m, 5 m, 6 m, 7 m, 8 m, 9 m, 10 m, 11 m, 12 m, 13 m
14 m, 15 m, 16 m, 17 m, 18 m, 19 m, 20 m, 25 m, 30 m, 35 m
Interface connector X21 - X31
Cross-section 2 x 2 AWG24, 2x 1.5 mm2
Lengths 1 m, 3 m, 7 m, 10 m, 15 m, 20 m,
25 m, 30 m, 35 m, 50 m
Bending radius 30 mm for single bending
Suitable for use in a cable carrier No

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4 Technical data
4.3.1 2nd data cable
4.3.2 Extensions
4.4 Resolver cable
4.4.1 Extensions
Connector type HAN Q12
Outside diameter 9 mm ±0.5 mm
Interface connector X21.1
Cross-section 2 x 2 AWG24, 2x 1.5 mm2
Lengths 1 m, 3 m, 7 m, 10 m, 15 m, 20 m,
25 m, 30 m, 35 m, 50 m
Bending radius 30 mm for single bending
Suitable for use in a cable carrier No
Connector type HAN Q12
Outside diameter 9 mm ±0.5 mm
Interface connector X31.1
Cross-section 2 x 2 AWG24, 2x 1.5 mm2
Lengths 1.6 m, 2 m, 3 m, 4 m, 5 m, 6 m,
7 m, 8 m, 9 m, 10 m, 11 m, 12 m,
13 m, 14 m, 15 m, 16 m, 17 m,
18 m, 19 m, 20 m, 25 m, 30 m,
35 m
Bending radius 100 mm for continuous bending
Suitable for use in a cable carrier Yes
Connector type HAN Q12
Outside diameter 10.6 mm ±0.3 mm
Interface connector XP
Cross-section 4 x 2 x 0.25 mm2
Lengths 1.3 m, 2 m, 3 m, 4 m, 5 m, 6 m,
7 m, 8 m, 9 m, 10 m, 11 m, 12 m,
13 m, 14 m, 15 m, 16 m, 17 m,
18 m, 19 m, 20 m, 25 m, 30 m
Bending radius 80 mm for continuous bending
Suitable for use in a cable carrier Yes
Connector type M23, 12 contacts
Outside diameter 8 mm ±0.5 mm
The max. difference in cable length between the individual channels
of the RDC box must not exceed 10 m.
Interface connector XPx.1
Cross-section 4 x 2 x 0.25 mm2

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Lengths 0.7 m, 1.4 m, 1.6 m, 2 m, 3 m, 4 m,
4.5 m, 5 m, 5.5 m, 6 m, 7 m, 7.5 m,
8 m, 9 m, 9.5 m, 10 m, 11 m,
11.5 m, 12 m, 13 m, 14 m, 15 m,
16 m, 17 m, 18 m, 19 m, 20 m
Bending radius 80 mm for continuous bending
Suitable for use in a cable carrier Yes
Connector type M23, 12 contacts
Outside diameter 8 mm ±0.5 mm

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5 Safety
5 Safety
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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