ROBOT

KR125K,KR150K

Description, Electrical Installations

eCopyright 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.

Length of documentation: LEERER MERKER pages

PD Interleaf

07.97.00 Ro/El/02/11 en 1
Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Connector pin allocation and cabling plans . . . . . . . . . . . . . . . . . . . 6

2 Ro/El/02/11 en 07.97.00
 Valid for KR 125 K/1
KR 125 L100 K/1
KR 125 L90 K/1
KR 150 K/1

1 General
The electrical installations of the robot form a separate assembly. It includes the “cable set”
(Fig. 1), containing all electric cables (Fig. 1 bis 3). The cable set has plug--and--socket con-
nections so that exchanges can be quickly carried out. This dispenses with the need for wir-
ing work.
The arrangement, designation and allocation of the cables may be noted from the various
diagrams. The connectors are provided with identification labels. The ground conductors are
fastened with cable lugs to threaded bolts.

2 Description
Installed on the base frame are three junction boxes (Fig. 1/5, 6, 7). The motor cables for
axes 1, 3 and 4 are grouped together in junction box X01 (5) and are wired up to a rectangular
flange--mounted connector. This connector is at the same time the connector on the robot
for the connecting cable (“motor cable”) between the robot and the control cabinet. The con-
nector consists of six separate connector modules. Each connector module is assigned a
particular motor connector (e.g. XM1), so that each motor cable can be replaced separately.
The ground conductors are connected to a ground conductor terminal (Fig. 13) in the junction
box (5).
The control cables for axes 1 to 6 are grouped together in junction box X02 (Fig. 1/6) and
are connected to an RDC board. Each control cable has a separate connector and can there-
fore be exchanged individually. The interface at the junction box (6) with the connecting cable
(“data cable”) between the robot and the control cabinet is formed by a 17--pole right--angle
connector.
Similarly to junction box X01, the motor cables for axes 2, 5 and 6 are grouped together in
junction box X03 (7). The ground conductors are connected to a ground conductor terminal
(Fig. 14) in the junction box (7).
At the back of the junction boxes (5, 6, 7) are Pg glands. From these glands, the cables are
routed to the base frame and from there via a common flexible tube A 1 (4) to the rotating
column. The flexible tube A 1 ensures a low--stress routing of the supply lines as well as re-
ducing the number of mechanical interface contours, without impairing the rotational motion
of axis 1. The cables for the drive units of axes 1 and 2 branch off in the rotating column.

07.97.00 Ro/El/02/11 en 3
 XM6 XP6

2 XM5 XP5 1

XM4 XP4

XM3
XP3

3
XM2
XP2

XM1
XP1

4
X01 X02 X03

5 6 7

1 Connectors for control cables

2 Connectors for motor cables
3 Ground conductors
4 Flexible tube A1
5 Junction box X01 for motor cables, axes 1, 3 and 4
6 Junction box X02 for control cables, axes 1 to 6
7 Junction box X03 for motor cables, axes 2, 5 and 6

Fig. 1 Cable set assembly

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Cable From To Cable From To
Ground conductor Bolt Bolt Control cable A 1 Connector X1 XP1
71--051--915 base frame rotating column 71--051--922
Bolt Bolt Control cable A 2 Connector X2 XP2
rotating column link arm 71--051--923
Bolt Bolt Control cable A 3 Connector X3 XP3
link arm arm 71--051--924
Motor cable A 1 Connector X30 XM1 Control cable A 4 Connector X4 XP4
71--051--916 71--051--925
Motor cable A 2 Connector X30.2 XM2 Control cable A 5 Connector X5 XP5
71--051--917 71--051--926
Motor cable A 3 Connector X30 XM3 Control cable A 6 Connector X6 XP6
71--051--918 71--051--927
Motor cable A 4 Connector X30 XM4 Connecting cable Connector X9 X31
71--051--919 71--051--853
Motor cable A 5 Connector X30.2 XM5 Mastering cable Connector X10 X32
71--051--920 71--051--854
Motor cable A 6 Connector X30.2 XM6
71--051--921

Fig. 2 Table of cables installed

XM4 XP4

NOTE: The exact arrangement of

junction boxes X01, X02 und X03 is
XM6 XP6 shown in Fig. 1.

XM5 XP5

XP3 XM3

Board

X6 X31
X32
XP2 XM2 X5
X4 X10
X3 X9
X2
XM1 XP1 X1

Modu
Modules
a to f

X31 a
b
X32 c
X02 d
e
X30 f
X01

X30.2
X03

Fig. 3 Electrical installations (block diagram)

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3 Connector pin allocation and cabling plans
Conn. X30, Pin no. Assignment
a1 A1/motor U
a2 not connected
a3 brake +

1 module
a4 A1/motor V
a5 brake --
a6 A1/motor W
b1 A3/motor U
b2 not connected
b3 brake +
b4 A3/motor V
b5 brake --
b6 A3/motor W
c1 A4/motor U
c2 not connected
c3 brake +
c4 A4/motor V
c5 brake --
c6 A4/motor W
d1 A1/motor U
d2 not connected
d3 not connected
d4 A1/motor V
d5 not connected
d6 A1/motor W
e1 A3/motor U
e2 not connected
e3 brake +
e4 A3/motor V
e5 brake --
e6 A3/motor W
f1 not connected
f2 not connected
f3 not connected
f4 not connected
f5 not connected
f6 not connected
PE ground conductor
PE ground conductor

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 Fig. 4 Connector
pin alloca-
tion X30

Connector X30.2, Assignment Connector X31, Assignment

Pin no. Pin no.

1 module
a1 A2/motor U 1 not connected
a2 not connected 2 GND
a3 brake + 3 24V
a4 A2/motor V 4 A1/CLKO
a5 brake -- 5 A1/CLKO
a6 A2/motor W 6 FSi
b1 A5/motor U 7 /FSi
b2 not connected 8 Di
b3 brake + 9 /Di
b4 A5/motor V 10 /FSo
b5 brake -- 11 FSo
b6 A5/motor W 12 /Do
c1 A6/motor U 13 Do
c2 not connected 14 /CLKi
c3 brake + 15 CLKi
c4 A6/motor V 16 not connected
c5 brake -- 17 not connected
c6 A6/motor W
d1 A2/motor U
d2 not connected
d3 not connected
d4 A2/motor V
d5 not connected
d6 A2/motor W
e1 not connected
e2 not connected
e3 not connected
e4 not connected
e5 not connected
e6 not connected
f1 not connected
f2 not connected
f3 not connected
f4 not connected
f5 not connected
f6 not connected

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PE ground conductor
PE ground conductor
Fig. 5 Connector pin al- Fig. 6 Connector
location X30.2 pin alloca-
Motor Brake Motor Resolver tion X31
temp.

M
S1 S3 S2 S4 R1 R2

XM1 U V W + -- 8 9 11 12 1 2 10 7
XP1
Connector
housing

Terminal
box
1 2 3 housing
X01
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30a X1
1 4 6
Rail

Fig. 7 Cabling plan, drive A 1

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 Motor Brake Motor Resolver
temp.

M
S1 S3 S2 S4 R1 R2

XM2 U V W + -- 8 9 11 12 1 2 10 7
XP2
Connector
housing

Terminal
box
1 2 3 housing
X03
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30.2a X2
1 4 6
Rail

Fig. 8 Cabling plan, drive A 2

Motor Brake Motor Resolver

temp.

M
S1 S3 S2 S4 R1 R2

U V W + -- 8 9 11 12 1 2 10 7
XM3 XP3
Connector
housing

Terminal
box
4 5 6 housing
X01
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30b X3
1 4 6
Rail

Fig. 9 Cabling plan, drive A 3

Motor Brake Motor Resolver

temp.

M
S1 S3 S2 S4 R1 R2

XM4 1 2 6 4 5 8 9 11 12 1 2 10 7
XP4

Connector
housing

Terminal
box
housing
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30c X4

Rail

Fig. 10 Cabling plan, drive A 4

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 Motor Brake Motor Resolver
temp.
M
S1 S3 S2 S4 R1 R2

XM5 1 2 6 4 5 8 9 11 12 1 2 10 7
XP5
Connector
housing

Terminal
box
housing
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30.2b X5

Rail

Fig. 11 Cabling plan, drive A 5

Motor Brake Motor Resolver

temp.

M
S1 S3 S2 S4 R1 R2

XM6 1 2 6 4 5 8 9 11 12 1 2 10 7
XP6
Connector
housing

Terminal
box
housing
1 4 6 3 5 2 1 9 8 3 7 6 5 4
X30.2c X6

Rail
Fig. 12 Cabling plan, drive A 6

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 M1 PE M3 PE X03

M4 PE

Junction box X01

for motor cables
PE

PE

PE
PE
A 1, A 3, A 4
Base of terminal
box
X02

X30

Fig. 13 Ground conductor installation X01

M2 PE M5 PE M6 PE

Base of terminal
box

Junction box X03

for motor cables
PE
PE

PE
PE
PE

A 2, A 5, A 6

Base frame
X01
Rotating
column

X30.2

Fig. 14 Ground conductor installation X03

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 X9
14 15 10 11 7 6 9 8 3 2 5 4 13 12

2 3 4 5 6 7 8 9 10 11 12 13 14 15
X31

Fig. 15 Cabling plan, RDC board connecting cable

Signal A0

Signal A1
24V

0V

X10
3 4 2 1

1 2 3 4
X32

Fig. 16 Cabling plan, mastering

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