06 Esc Safety Circuit Ed05 en PDF

Chapter 6
ESC Electronic Safety Circuit
Table of contents
1. ESC Electronic Safety Circuit.........................................................3
2. Fault detection ESC ........................................................................15
3. X11 Jumper plug .............................................................................21
4. ESC Gateway .................................................................................23
5. Wiring diagrams ESC......................................................................31

Page 2 of 32 Workbook SE KR C2 edition2005 01.06.00
1. ESC Electronic Safety Circuit
Workbook SE KR C2 edition2005 01.06.00 Page 3 of 32

Electronic Safety Circuit (ESC)
MFC
passive node
ESC board
KPS600
KCP
ESC master
The Electronic Safety Circuit (ESC) is a dual-channel, computer-aided safety

system, that functions with a closed ring bus.
The ESC devices are nodes that are connected to each other via power supply
and communication lines.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka.com
I 31.01.2006 I College I NoLi I 1
Copyright by KUKA Roboter GmbH College
ESC circuit nodes
ESC IN ESC OUT
TA (A) Test output Test output TA (B)

LNA Local E-Stop Local E-Stop LNA
ESC ESC
ENA External E-Stop External E-Stop ENA
Enabling switch Chip A Chip B Enabling switch
ZS1 ZS1
ZS2 En. switch (panic) En. switch (panic) ZS2
Inputs
Inputs
BA (A) Automatic Test BA (T)

QE Qualifying input Qualifying input QE
E2 Special keyswitch Special keyswitch E2
BS Operator safety Operator safety BS
AF Enable drives Activate drives AA
LNA=Local Emergency Stop

BA (A)
BA (T)
AE=Drives On
LNA
LNA
Outputs
AE
AE
BA=Operating mode

ESC nodes, inputs and outputs
Failsafe inputs
NA Local Emergency Stop
ENA External Emergency Stop
ZS1 Enabling switch
ZS2 Enabling, panic position
BA Operating mode (Test / Auto)
QE Qualifying input (loading stations, range limitation)
BS Operator safety (safety gates)
Controller inputs
AA Activate drives (Drives ON)
AF Drives enable (Drives OFF)
Failsafe outputs
AE Drives ON (drives contactor)
LNA Local Emergency Stop
BA Operating mode (Test / Auto)
Errors recognized by the ESC circuit
Cross-connection between the two channels of an input signal

Cross-connection between one input channel and the supply voltage
Communication error (e.g. bus cable discontinuity)
Hardware fault (e.g. defective relay contacts of the failsafe outputs)
Defective ESC chip

ESC - Wiring of the 2-channel inputs
TA24V(B)
TA24V (A)
ENA (A)
ENA (B)
ENA = External EMERGENCY STOP
ESC - Monitoring of the failsafe inputs
70 s 70 s
ESC chip A TA (A)
ENA (A)
70 s 70 s external
E-Stop
ESC chip B TA (B)
ENA (B)
Signals of channels A and B are offset over

time
The maximum cable length for the input signals is about 100 m
due to the monitored time period for the return signals of max. 2 ms.

ESC - Monitoring of the failsafe outputs
ESC chip A 70 s 70 s
Comparison
Relay, e.g. LNA

ESC chip B
Comparison
70 s 70 s
Each ESC chip sends a bit pattern to its outputs and

compares the return signals with this pattern.
ESC board variants
For the KR C2edition2005, different ESC boards can be

installed for a variety of configurations and in accordance with
customer requirements.
The assignment of the individual connectors, relays and fuses
remains the same, however.
The fuses are rated for up to 35 V. On the boards there is a red
LED for each fuse, which lights up if the fuse is defective.
The following variants of the ESC boards are in use:
CI3 Standard ESC board without node
CI3 Extended ESC board with node
CI3 Bus ESC board for connection to SafetyBus p
CI3 Tech ESC board for RoboTeam, shared

pendant, SafeRobot

CI3 Standard
X2KPS600 X3MFC3
X18MFC3
X19RDW
(Power supply)
X4ext. BA
Local X7I/O module

E-STOP K9
ESC Reset X6X11
K3 (ext. power supply)
K4 X31
X1
X5KCP (ESC)
Cabinet internal fan
Power
supply
X16
CC and CCC interface
X21KCP
(CAN and power
supply)
Reset button
X8 X22
Servo disconnect Inputs / outputs peripheral
interface X11
CI3 Extended
K2
Drives ON
K1
BA Test
K7
BA Auto K8
K3
Local
E-STOP
K4 Reset button
X12
Peripheral outputs

CI3 Bus
X13
Gateway / bus coupler
interface
X22
Inputs / outputs peripheral
interface X11
CI3 Tech
X18MFC (RoboTeam option)
X19
RoboTeam lamp
Local
E-STOP
K3
K4
X26 KUKA
Guiding Device
X23 Safe RDW X25 RoboTeam IN X24 RoboTeam OUT


CI3 board interface assignment - Part 1
Interface Assignment
X1 Power supply with/without battery backup
X2 Ribbon cable to KPS 600
X3 Connection to MFC3 via Connector Print
X4 Inputs to the MFC3, stationary operating mode switch
X5 KCP, ESC bus
X6 Customer interface X11, internal / external power supply
X7 User I/Os to peripheral interface, 16 inputs / 20 outputs via CAN bus (optional)
X8 Servo Disconnect, E-STOP from KGD (optional)

X11 E7 special keyswitch (VW option), RoboTeam test outputs
X12 Customer interface X11, outputs: internal E-Stop, operating mode, Drives ON
X13 Jumper / interface to other safety bus systems
X16 Interface for CC (Cobra Control) and CCC (Common Control Cabinet)
X17 Control and return signals for external main contactor (optional)
X18 Interface to MFC3, ESC Reset, fan monitoring, RoboTeam (optional)
CI3 board interface assignment - Part 2
Interface Assignment
X19 Interface to lamp for RoboTeam (optional)
X20 Selection Switch on Shared Pendant (RoboTeam option)
X21 Interface to KCP, CAN bus and buffered 27 V power supply
X22 Connection to customer interface X11, inputs: ENA, BS, ext. enabling
X23 Interface to SafeRDC (optional)
X24 RoboTeam functionalities
X25 RoboTeam functionalities
X26 KUKA Guiding Device KGD interface (optional)
X27 MultiPowerTap MPT DeviceNet from MFC3

X28 MultiPowerTap MPT DeviceNet OUT1
X29 MultiPowerTap MPT DeviceNet OUT2
X30 Ext. ESC reset relay
X31 Internal cabinet fan connection

CI3 board assignment of fuses
Fuse Value Function

F1 2A AE output at X12
F2 2A Cabinet fan monitoring
F3 2A Power supply, contactor control AE
F10 3A Power supply, ESC circuit
F12 4A 27 V without battery backup at X12
F13 4A 27 V without battery backup at X6 for internal ESC supply
F14 4A Output AE
F15 7.5 A Output AE

F16 7.5 A 27 V without battery backup at X12
F21 2A RoboTeam lamp (optional)
F23 2A RDC supply
F24 2A Supply, multipower tap MPT
CI3 board relay functionality
Relay Function
K1 Drives ON
K2 Drives ON
K3 Local Emergency Stop
K4 Local Emergency Stop
K7 Operating mode TEST / AUTO
K8 Operating mode TEST / AUTO
K9 ESC Reset

CI3-Board diagnosis LEDs for supply voltage and fusing
LED Color Description

1 Red Voltage monitoring F10 3A, supply voltage for ESC
2 Red Voltage monitoring F13 4A, 27 Volt unbuffered at X6 for the
internal supply of the ESC
3 Red Voltage monitoring F3 2A, Supply of the relay control (Output
AE)
4 Red Voltage monitoring F12 4A, 27Volt unbuffered at X12
5 Red Voltage monitoring F16 7,5A, 24 Volt unbuffered at X12
6 Red Fuse monitoring F1 2A, Output AE at X12
8 Red Fuse monitoring F15 7,5A Output AE at X12
9 Green Voltage monitoring VCC buffered
10 Red Fuse monitoring F7 2A, 24 Volt buffered MPT
11 Red Fuse monitoring F4 2A, switching lamp RoboTeam
12 Red Fuse monitoring F6 2A, 24 Volt buffered RDW
14 Green Voltage monitoring VCC unbuffered
15 Green Voltage monitoring 5V ESC-node
16 Red Fuse monitoring F8 2A, 24 Volt unbuffered inside fan
CI3-Board diagnosis LEDs for ESC-nodes (Low-level-diagnosis)

17 Green ESC-Output KCP OK
18 Red ESC-Output KCP NOK
19 Red ESC-Output KPS NOK
20 Green ESC-Output KPS OK
21 Green ESC-Output local ESC node OK
22 Red ESC-Output local ESC node NOK
23 Red ESC-Output Safetybus Gateway NOK
24 Green ESC-Output Safetybus Gateway OK
25 Green ESC-Output X6 OK
26 Red ESC-Output X6 NOK
27 Red ESC-Output MFC NOK
28 Green ESC-Output MFC OK
29 Green Voltage monitoring 3,3 Volt for RoboTeam PLDs

KR C2 braking reactions
Test Auto
(T1 or T2) (Automatic or automatic external)
E-STOP Path-oriented braking Path-maintaining braking
Enabling switch Path-oriented braking ----
Operator safety ---- Path-maintaining braking
Drives OFF Path-oriented braking
Op. mode change Path-oriented braking
Encoder error Short-circuit braking

Motion enable Ramp-down braking
Stop key Ramp-down braking
KR C2 braking reactions
Drives Intermediate Short-circuit Brakes Software

contactor circuit braking
voltage relays
Ramp- Remains Remains charged Not applied Remain open Robot is stopped along
switched on a normal braking ramp
down braking
Path- Opened with a Remains charged Not applied Applied after In the 1 s time interval
delay of 1 s for 1 s and is then 1s the KRC2 brakes the
maintaining continuously robot with a steeper
braking discharged braking ramp
Path-oriented Switched off Discharged Not applied Applied The controller attempts
immediately immediately immediately to brake the robot on the
braking path with the remaining
intermediate circuit
voltage.
When the intermediate
circuit voltage is no
longer sufficient for
doing so, short-circuit
braking is activated.
Short-circuit Switched off High-speed Applied Applied ----

immediately discharge immediately immediately
braking

2. Fault detection ESC

Testing the failsafe inputs
70 s 70 s
TA24V(A)
Chip A
NA (A)
70 s 70 s
TA24V(B)
Chip B
NA (B)
Signals of channels A and B are offset over

time
Each chip sends a bit pattern to its outputs and compares the
return signals with this pattern.
In the event of disparity, the outputs are set to a safe state.
Testing the failsafe outputs
70 s 70 s
LNA
Comparison
(A)
Chip A
RLNA
(A)
LNA
RLNA
Comparison
(B)
70 s 70 s
Chip B
LNA
(B)
Each chip sends a bit pattern to its outputs and compares the
return signals with this pattern.

Drives contactor return signal
RAE2(A) AE (A)
70 s 70 s
Chip A Comparison RAE (A)
K1
RAE 24 V
Chip B
Comparison
(B)
70 s 70 s
AE
(B)
Each chip compares the state of the outputs with the state of the return
signals. In the event of disparity, the outputs are set to a safe state.
Relay test
K3 K4 AUTO
TA5 V (A) RREL

LNA TEST
Open = operating mode

selected
The signal sent from the TA must be applied once more

to the input of the RREL (return relay).

Reciprocal monitoring of the nodes
Node n Node n+1
Chip A Chip A
Chip B Chip B
Chip A compares the input signals with Chip B compares the input signals with
the protocol of the previous node, sets the protocol of the previous chip, sets
the outputs and the sends on the the outputs and the sends on the
protocol protocol
CI3-Board diagnosis LEDs for supply voltage and fusing

1 Red Voltage monitoring F10 3A, supply voltage for ESC
2 Red Voltage monitoring F13 4A, 27 Volt unbuffered at X6 for the
internal supply of the ESC
3 Red Voltage monitoring F3 2A, Supply of the relay control (Output
AE)
4 Red Voltage monitoring F12 4A, 27Volt unbuffered at X12
5 Red Voltage monitoring F16 7,5A, 24 Volt unbuffered at X12
8 Red Fuse monitoring F15 7,5A Output AE at X12
9 Green Voltage monitoring VCC buffered
10 Red Fuse monitoring F7 2A, 24 Volt buffered MPT
11 Red Fuse monitoring F4 2A, switching lamp RoboTeam
12 Red Fuse monitoring F6 2A, 24 Volt buffered RDW
14 Green Voltage monitoring VCC unbuffered
15 Green Voltage monitoring 5V ESC-node
16 Red Fuse monitoring F8 2A, 24 Volt unbuffered inside fan

CI3-Board diagnosis LEDs for ESC-nodes (Low-level-diagnosis)

17 Green ESC-Output KCP OK
18 Red ESC-Output KCP NOK
19 Red ESC-Output KPS NOK
20 Green ESC-Output KPS OK
21 Green ESC-Output local ESC node OK
22 Red ESC-Output local ESC node NOK
23 Red ESC-Output Safetybus Gateway NOK
24 Green ESC-Output Safetybus Gateway OK
25 Green ESC-Output X6 OK
26 Red ESC-Output X6 NOK
27 Red ESC-Output MFC NOK
28 Green ESC-Output MFC OK
29 Green Voltage monitoring 3,3 Volt for RoboTeam PLDs

3. X11 Jumper plug

X11 Jumper plug
The external safety circuit of the robot can be short-circuited

using the X11 jumper plug.
When troubleshooting in the safety circuit it then becomes possible

to establish whether the source of the fault is in the control cabinet
or in the periphery.
The jumper plug detailed in this documentation relates only to the

KUKA standard X11.
All other assignments (resulting from previously defined

standards) are to be taken from the appropriate wiring diagrams.
When using the SafetyBUS p Gateway the ESC circuit of the robot
can be started by means of a HIGH signal to both of the start-up pins
(INB(A) and INB(B)), without a connection to the PSS.
X11 KUKA standard jumper plug

37 1
Not connected Test output (A)
38 2
Test output (A) Local E-STOP (A)
39 3
Test output (B) Local E-STOP (A)
40 4
Not connected External E-STOP (A)
41 5
Test output (A) Test output (A)
42 6
Drives OFF external Ext. enabling switch (A)
50 7
QE (A) Test output (A)
51 8
QE (B) Safeguard (A)
54 25
ESC IN (B) Test output (B)
70 26
ESC OUT (B) Safeguard (B)
71 19
ESC OUT (A) Test output (B)
88 20
+24 V external ESC Local E-STOP (B)
89 21
0 V external ESC Local E-STOP (B)
106 22
+24 V internal External E-Stop (B)
107 23
0 V internal Test output (B)
108 24
ESC IN (A) External enabling switch (B)

4. ESC Gateway

KUKA safety systems
KR C2
SafetyBUS p
KUKA safety technology
Advantages of KUKA safety technology on KR C2:

Electronic safety logic
Open to other standards
Decentralized structure is possible
KR C2
KPS
KCP MFC
CI
Gate-
way
SafetyBUS p

SafetyBUS p connection
The use of the SafetyBUS p Gateway

SafetyBUS p enables:
Gateway Electronic coupling of the ESC circuit to SafetyBUS p
Dual-channel link
Safety category 3
PILZ safety
controller (PSS)
Robot
safety
system (ESC)
e.g. working range

monitoring
SafetyBUS p
Gateway
SafetyBUS p Field bus I/Os

Variants of the SafetyBUS p Gateway
Two different variants of the SafetyBUS p Gateway are currently

used by KUKA:
SafetyBUS p Gateway and
SafetyBUS p Gateway A
When replacing or ordering the SafetyBUS p Gateway, always

pay attention to the correct article number!
SafetyBUS p Gateway
SafetyBUS p
SafetyBUS p Chip B
Chip A
X2 X1 X11
ESC chip A SafetyBUS p
S2
S1
F1
X3 ESC
Chip B
Gateway Gateway
X6
Chip A Chip B

SafetyBUS p Gateway technical data
SafetyBUS p Gateway technical data:
Supply voltage: 24 V DC (permissible range: 20 V 33 V DC)

Inputs/outputs: 14 digital inputs 24 V DC pulsed
(resistive load only)
4 digital inputs 24 V DC, unpulsed
2 digital outputs (channel A) 24 V DC
(resistive / inductive load)
2 digital outputs (channel B) GND DC
1 A each (short-circuit proof)
Temperature ranges: Operating temperature +20 C to +70 C
Storage temperature +5 C to +80 C
SafetyBUS p connection: Via PILZ SafetyBUS p connector D0,
D1, D2, or D3
SafetyBUS p Gateway A
SafetyBUS p
SafetyBUS p Chip B
Chip A
X2 X1 X11
ESC chip A SafetyBUS p
S2
S1
F1
X3 ESC
Chip B
Gateway Gateway X7 X8
X6
Chip A Chip B

SafetyBUS p Gateway technical data
SafetyBUS p Gateway A technical data:
Supply voltage: 24 V DC (permissible range: 20 V 33 V DC)

Inputs/outputs: 16 digital inputs 24 V DC pulsed
4 digital inputs 24 V DC, unpulsed
4 digital outputs (channel A) 24 V DC
4 digital outputs (channel B) GND DC
1 A each (short-circuit proof)
Temperature ranges: Operating temperature +20 C to +70 C
Storage temperature +5 C to +80 C
SafetyBUS p connection: Via PILZ SafetyBUS p connector D0,
D1, D2, or D3; 5 V for the supply of the
Cu / fiber-optic converters
SafetyBUS p Gateway - Interfaces
Designation Meaning
X1: Peripheral connector inputs and outputs
X2: SafetyBUS p connection
X3: Connector to CI bus board
X6 Connector for wiring output A1 and return signals
S1: Rotary selector for setting the SafetyBUS p address (tens selector)
S2 Rotary selector for setting the SafetyBUS p address (units selector)
F1 Supply voltage fuse, 2A mT

SafetyBUS p Gateway
H1...H5 S2 S1
SafetyBUS p
Gateway with
cover
CI bus
board
LED Designation Color Function

H1 LED BUS green Status of SafetyBUS p (lit = OK)
H2 LED Device_R red Device status (lit = fault, H3 is off)
H3 LED Device_G green Device status (lit = OK, H2 is off)
H4 LED GR_A green Group status, group A (lit = A started)
H5 LED GR_B green Group status, group B (lit = B started)
BA Operating mode
ENA External E-Stop
BS Operator safety
SafetyBUS p Gateway
QE Local robot enable

Robot safety bus (ESC)
E2 Special keyswitch
SafetyBUS p ZS Enabling switch
AF Drives enable
AA Activate drives
RES ESC circuit reset
LNA Local E-STOP

RE Robot switched on
AE Drives ON
BA Operating mode
KR C2 Robot profile in the PSS

SafetyBUS p - I/O description
Inputs
BA Operating mode Always 0; reserved for later use
ENA External E-STOP System E-STOP; directed to the ESC of the robot
BS Operator safety Safety signal from safety gate or light barrier
QE Local robot enable Interlock of the robot, independent of the operating mode (does not affect other
devices in the safety bus)
E2 Special keyswitch Customer-specific signal
ZS Enabling switch Enabling signal in manual mode via PSS
AF Drives enable Drives OFF
AA Activate drives 0? 1 edge in auto mode switches drives on
RES Reset ESC circuit Reset ESC circuit
Outputs
LNA Local E-STOP Robot in E-STOP
RE Robot switched on Robot is switched on (voltage on)
AE Drives ON Robot drives are ON (drives contactor energized)
BA Operating mode Selected operating mode (AUTO/ TEST)
INB Start-up Overriding the external safety circuit. The drives contactor can only pick up in
TEST mode
Connection examples
Connection of a contactor with

external power supply Connection of a pushbutton
with external power supply
Plus_24V-A0
A0 (A)
TA24V (B)
X1:22
TA24V (A)
K1 X1:20
A0 (B)
X1
RAE2(A) D0 (A)
X1:1
D0 (B)
Plus_24V-A0 X1:2
24 V DC
GNDS-A0
external

5. Wiring diagrams ESC

CI3-Standard
TA24V (A) TA5V (A)

AE (A) AE (A)
TA24V (B) TA5V (B)
RAE (A) RAE (A)
24V
RAE2 (A) RAE2 (A)
ENA (A) K1 ENA (A)
AE (B) AE (B)
ESC-Status-signals
ENA (B) RAE (B) ENA (B) RAE (B)
E-Stop
LNA (A) RAE2 (B) LNA (A) RAE2 (B)
LNA (B) LNA (A) LNA (B) LNA (A)
ZS1 (A) RLNA (A) ZS1 (A) RLNA (A)
ZS1 (B) LNA (B) ZS1 (B) LNA (B)
ZS2 (A) RLNA (B) ZS2 (A) RLNA (B)
ZS2 (B) ENA (A) Multipoint ZS2 (B) ENA (A)
RENA (A) Enabling RENA (A)
BS (A) BS (A)
ENA (B) switch ENA (B)
BS (B) BS (B)
RENA (B) RENA (B)
OPM AUTO BA AUTO
AAUTO AAUTO
OPM TEST BA TEST
RAUTO RAUTO
QE (A) OPM- QE (A)
ATEST ATEST
QE (B) Selector QE (B)
RTEST RTEST
E2 (A) RREL E2 (A)
ESC OUT (B)

ESC OUT (A)
ESC OUT (B)

ESC OUT (A)
ESC IN (B)
ESC IN (A)
ESC IN (B)
ESC IN (A)
E2 (B) Push Button Drives On E2 (B)
Ground Input 1...4

ESC_Reset_MFC
AF(A) AA
+VCC
+VCC
+VCC
GND
GND
GND
AA(B) AF
AF_MFC
Push Button Drives Off
AF_X8
Input 1
Input 2
Input 3
Input 4
9 10 15 16 23 24 17 18 13 14 11 12 21 22 25 26 19 20 6 5 3 4 7 8 2 1 31 30 28 29 27 5 6 4 3 2 1 9 8 7 25 13 12 24 23 11 7 16 17 18 19
X2 X5 X18 X3
CI3-Standard
K3 K4 K3 K4
X13 Jumper
2A
2A
K9
4A
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 16 35 17 36 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 8 1 2 3 4 1 2 3 4 5 6 7 8 9 10
7
LNA(A)_O
LNA(B)_O
ENA (A)
ENA (B)
ZS1 (A)
ZS1 (B)
LNA(A)_I
LNA(B)_I
QE (A)
QE (B)
BS (A)
BS (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
E2 (A)
E2 (B)
AA(B)
AF(A)
27V unbuffered
GND unbuffered
27V buffered
GND buffered
24V_OUT1_ESC
24V_OUT2_ESC
NA(A)_KGD
NA(B)_KGD
24V_IN_6_MFC
24V_IN_7_MFC
27V_unbuffered
GND_unbuffered
24V_IN1_ESC
24V_IN2_ESC
GND_buffered
ESC OUT (B)

ESC OUT (A)
+VCC external
OPM Auto
OPM Auto
GND external
OPM Test
OPM Test
IN_1_24V
IN_2_24V
IN_3_24V
IN_4_24V
+VCC internal
27V_buffered
AF_X16
GND internal
VCC_CI
AF_X8
ESC IN (A)
ESC IN (B)
NA(A)
NA(B)
AF_X22
AF_X16
X22 X8 X16 X6 X1 X4
KUKA Roboter GmbH,Hery- Park 3000, D- 86368 Gersthofen, Tel.: +49 (0) 8 21/45 -331906, Fax: +49 (0) 8 21/45 33
- 2340, http:// www.kuka.com I 14.07.2005 I College I NoLi I 1
CI3-Extended
TA24V (A) TA5V (A)

AE (A) AE (A)
TA24V (B) TA5V (B)
RAE (A) RAE (A)
24V
RAE2 (A) RAE2 (A)
ENA (A) K1 ENA (A)
AE (B) AE (B)
ESC-Status-signals
E-Stop
BS (A) BS (A)
BS (B) BS (B)
RENA (B) RENA (B)
OPM AUTO OPM AUTO
AAUTO AAUTO
OPM TEST OPM TEST
RAUTO RAUTO
QE (A) OPM- QE (A)
ATEST ATEST
RTEST RTEST
E2 (A) RREL E2 (A)
ESC OUT (B)

ESC OUT (A)
ESC OUT (B)

ESC OUT (A)
ESC IN (B)
ESC IN (A)
ESC IN (B)
ESC IN (A)
Ground Input 1...4

ESC_Reset_MFC
AF(A) AA
+VCC
+VCC
+VCC
GND
GND
GND
AA(B) AF
AF_MFC
AF_X8
Input 1
Input 2
Input 3
Input 4
9 10 15 16 23 24 17 18 13 14 11 12 21 22 25 26 19 20 6 5 3 4 7 8 2 1 31 30 28 29 27 5 6 4 3 2 1 9 8 7 25 13 12 24 23 11 7 16 17 18 19
X2 X5 X18 X3
CI3-Extended
K3 K4 K3 K4
5V
X13 Jumper
ESC OUT (B)
ESC OUT (A)
+VCC
K1
GND
RAE2 (A) TA5V (A)
ESC IN (B)
ESC IN (A)
AE (A) TA5V (B)
RAE (A) ENA (A)
4A
2A
K1 K2 K1 K2 RAE (B) ENA (B)

AE (B) LNA (A)
RAE2 (B) LNA (B)
LNA (A) ZS1 (A)
RLNA (A) ZS1 (B)
LNA (B) ZS2 (A)
2A
2A
RLNA (B) ZS2 (B)
BS (A)
ENA (A)
BS (B)
RENA (A)
ENA (B) OPM AUTO
RENA (B) OPM TEST
AAUTO QE (A)
RAUTO QE (B)
ATEST E2 (A)
K7 K8
RTEST E2 (B)
K7 K8 AF(A)
AA(B)
K9
4A
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 16 35 17 36 18 19 37 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 8 1 2 3 4 1 2 3 4 5 6 7 8 9 10
7
LNA(A)_O
LNA(B)_O
ENA (A)
ENA (B)
OPM TEST
ZS1 (A)
ZS1 (B)
OPM COM
OPM AUTO
LNA(A)_I
LNA(B)_I
AE_OUT_7,5A
QE (A)
QE (B)
BS (A)
BS (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
E2 (A)
E2 (B)
AA(B)
AF(A)
AE_OUT_4A
AE_OUT_2A
27V unbuffered
GND unbuffered
27V buffered
GND buffered
24V_OUT1_ESC
24V_OUT2_ESC
NA(A)_KGD
NA(B)_KGD
24V_IN_6_MFC
24V_IN_7_MFC
27V_unbuffered
GND_unbuffered
24V_IN1_ESC
24V_IN2_ESC
GND_buffered
AE_IN
AE_IN
ESC OUT (B)

ESC OUT (A)
+VCC external
GND external
IN_1_24V
IN_2_24V
IN_3_24V
IN_4_24V
27V_buffered
+VCC internal
AF_X16
GND internal
BA Auto
BA Auto
VCC_CI
AF_X8
ESC IN (A)
ESC IN (B)
BA Test
BA Test
NA(A)
NA(B)
AF_X22
AF_X16
X22 X12 X8 X16 X6 X1 X4
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka.com I 14.07.2005 I College I NoLi I 1
CI3-Bus
TA24V (A) TA5V (A)

AE (A) AE (A)
TA24V (B) TA5V (B)
RAE (A) RAE (A)
24V
RAE2 (A) RAE2 (A)
ENA (A) K1 ENA (A)
AE (B) AE (B)
ESC-Status-signals
E-Stop
BS (A) BS (A)
BS (B) BS (B)
RENA (B) RENA (B)
BA AUTO OPM AUTO
AAUTO AAUTO
BA TEST OPM TEST
RAUTO RAUTO
QE (A) OPM- QE (A)
ATEST ATEST
RTEST RTEST
E2 (A) RREL E2 (A)
ESC OUT (B)

ESC OUT (A)
ESC OUT (B)

ESC OUT (A)
ESC IN (B)
ESC IN (A)
ESC IN (B)
ESC IN (A)
Ground Input 1...4

ESC_Reset_MFC
AF(A) AA
+VCC
+VCC
+VCC
GND
GND
GND
AA(B) AF
AF_MFC
AF_X8
Input 1
Input 2
Input 3
Input 4
9 10 15 16 23 24 17 18 13 14 11 12 21 22 25 26 19 20 6 5 3 4 7 8 2 1 31 30 28 29 27 5 6 4 3 2 1 9 8 7 25 13 12 24 23 11 7 16 17 18 19
X2 X5 X18 X3
CI3-Bus
ESC-node
internal ring
X1
SafetyBus p
External ring
X13 X2
2A
2A
K9
4A
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 8 1 2 3 4 1 2 3 4 5 6 7 8 9 10
7
ENA (A)
ENA (B)
ZS1 (A)
ZS1 (B)
INB (A)
INB (B)
QE (A)
QE (B)
Pilz SafetyBus p
BS (A)
BS (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
TA (A)
TA (B)
E2 (A)
E2 (B)
AA(B)
AF(A)
27V unbuffered
GND unbuffered
27V buffered
GND buffered
24V_OUT1_ESC
24V_OUT2_ESC
NA(A)_KGD
NA(B)_KGD
24V_IN_6_MFC
24V_IN_7_MFC
27V_unbuffered
GND_unbuffered
24V_IN1_ESC
24V_IN2_ESC
GND_buffered
ESC OUT (B)

ESC OUT (A)
+VCC external
GND external
GND internal
IN_1_24V
IN_2_24V
IN_3_24V
IN_4_24V
27V_buffered
+VCC internal
AF_X16
BA Auto
BA Auto
VCC_CI
AF_X8
ESC IN (A)
ESC IN (B)
BA Test
BA Test
NA(A)
NA(B)
IN / OUT
AF_X22
AF_X16
X22 X8 X16 X6 X1 X4
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka.com I 14.07.2005 I College I NoLi I 1

06 Esc Safety Circuit Ed05 en PDF

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06 Esc Safety Circuit Ed05 en PDF

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Chapter 6

ESC Electronic Safety Circuit

2. Fault detection ESC ........................................................................15

3. X11 Jumper plug .............................................................................21

4. ESC Gateway .................................................................................23

5. Wiring diagrams ESC......................................................................31

Workbook SE KR C2 edition2005 01.06.00 Page 3 of 32

The Electronic Safety Circuit (ESC) is a dual-channel, computer-aided safety

ESC circuit nodes

ESC IN ESC OUT

TA (A) Test output Test output TA (B)

BA (A) Automatic Test BA (T)

LNA=Local Emergency Stop

Page 4 of 32 Workbook SE KR C2 edition2005 01.06.00

Errors recognized by the ESC circuit

Cross-connection between the two channels of an input signal

Workbook SE KR C2 edition2005 01.06.00 Page 5 of 32

ENA = External EMERGENCY STOP

ESC - Monitoring of the failsafe inputs

ESC chip A TA (A)

ESC chip B TA (B)

Signals of channels A and B are offset over

Page 6 of 32 Workbook SE KR C2 edition2005 01.06.00

Relay, e.g. LNA

Each ESC chip sends a bit pattern to its outputs and

ESC board variants

For the KR C2edition2005, different ESC boards can be

The following variants of the ESC boards are in use:

CI3 Standard ESC board without node

CI3 Extended ESC board with node

CI3 Bus ESC board for connection to SafetyBus p

CI3 Tech ESC board for RoboTeam, shared

Workbook SE KR C2 edition2005 01.06.00 Page 7 of 32

Local X7I/O module

Page 8 of 32 Workbook SE KR C2 edition2005 01.06.00

X23 Safe RDW X25 RoboTeam IN X24 RoboTeam OUT

Workbook SE KR C2 edition2005 01.06.00 Page 9 of 32

X8 Servo Disconnect, E-STOP from KGD (optional)

CI3 board interface assignment - Part 2

X27 MultiPowerTap MPT DeviceNet from MFC3

Page 10 of 32 Workbook SE KR C2 edition2005 01.06.00

Fuse Value Function

F15 7.5 A Output AE

CI3 board relay functionality

Workbook SE KR C2 edition2005 01.06.00 Page 11 of 32

LED Color Description

CI3-Board diagnosis LEDs for ESC-nodes (Low-level-diagnosis)

LED Color Description

Page 12 of 32 Workbook SE KR C2 edition2005 01.06.00

Enabling switch Path-oriented braking ----

Operator safety ---- Path-maintaining braking

Drives OFF Path-oriented braking

Op. mode change Path-oriented braking

Encoder error Short-circuit braking

Drives Intermediate Short-circuit Brakes Software

Short-circuit Switched off High-speed Applied Applied ----

Workbook SE KR C2 edition2005 01.06.00 Page 13 of 32

Workbook SE KR C2 edition2005 01.06.00 Page 15 of 32

Signals of channels A and B are offset over

Testing the failsafe outputs

Page 16 of 32 Workbook SE KR C2 edition2005 01.06.00

Chip A Comparison RAE (A)

TA5 V (A) RREL