ROBOT

KR QUANTEC

Assembly and Operating Instructions

Energy Supply System, Handling, A3 -- A6

Art. no. 00--202--507
00--202--508
00--202--509

Issued: 02 Jul 2014 Version: 02

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e Copyright 2014

KUKA Roboter GmbH

Zugspitzstrasse 140
D--86165 Augsburg
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 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, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

Translation of the original documentation

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Contents

1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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 Assembly and Operating Instructions

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1 Description

Valid for KR QUANTEC

1 Description
For use in certain production technologies, the robot can be equipped with an “Energy supply
system, handling, A3 -- A6” installed in the area between the arm and the in--line wrist (Fig. 1).
The energy supply system consists of a “dress package A3 -- A6” for transmitting the energy,
fluids and signals typical of the technological process concerned, and the holders for energy
supply system required for attaching it to the robot.
The energy supply system A3 -- A6 accommodates the cables and hoses and ensures that
they are guided with minimum stress throughout the permitted working envelope.
The design of the energy supply system is suitable for approximately 90% of all applications
in terms of reach and resistance to wear. There may, of course, be applications for which this
version is of only limited use. A special version is required in such cases, or a corresponding
adaptation of the energy supply system.
The energy supply system A3 -- A6 (Fig. 1) is fastened to the arm and in--line wrist in such
a way that it does not impair the robot motion and is protected against damage. The dress
package is secured inside a K box that is installed on the arm of the robot. It is secured in
holder A6 (11) in a ball joint (12) and at its start on interface A3 in the box clamp (2). The
mounting on axis 6 is designed to permit the flexible tube to rotate but to prevent it from mov-
ing in an axial direction. The multiple--piece spring stubs (5) pull the dress package (6) back
into its starting position in the K box (4) after every motion and keep it lightly tensioned. Using
the protector (7), the compression springs must be adjusted for each application in order to
ensure optimized spring travel. It must be ensured, however, that the compression springs
are not completely compressed as this could cause damage to the system.

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 Assembly and Operating Instructions

1 2 3 4 5

12

6
11
7

10

9
8

1 Protector 7 Protector (adjustment of spring)

2 Box clamp 8 Link arm
3 Holder, K box 9 Interface A3
4 K box 10 Tool
5 Spring stub 11 Holder A6
6 Dress package 12 Ball joint

Fig. 1 Energy supply system, handling, A3 -- A6

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1 Description (continued)

To prevent the flexible tube (Fig. 2/8) from chafing against the robot body during extreme
movements, protectors (7) are provided at the corresponding points on the tube. In operation
of the robot, the protectors must be adjusted so that only the protectors slide over the robot
arm and in--line wrist and not the flexible tube itself.
The flexible tube is mounted via the ball holder (10) in holder A6, which allows a large swivel
range, thus increasing the service life of the flexible tube. The compression springs are ad-
justed via the spring holders (6) and the protector (3). The spring stubs (4) are held together
with spring connectors (5), which also serve as slides. The compression springs are sup-
ported in the spring holder (6).

A3 A6

200 10 700 10
50 10
250/400/550 10

1 2 3 4 5 6 7 8 9 10

1 Clamping piece 6 Spring holder

2 Support shell 7 Protector
3 Protector for adjusting compression spring 8 Flexible tube
4 Spring stub 9 Sleeve shell
5 Spring connector 10 Ball holder

Fig. 2 Structure of flexible tube

The energy supply system is connected at interfaces A3 (Fig. 1/9) and A6 by means of
unions for the hoses and connectors for the electric cables. Interface A3 is installed on the
side of the arm, while interface A6 is located on the tool (10).
When routing supply lines to the tool, the minimum bending radius of the individual supply
lines (approx. 10x the diameter, 200 mm for fiber--optic cables and flexible tube) must be ob-
served, also during operation.
The responsibility for the function and safety of the energy supply system is borne by the
user.

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 Assembly and Operating Instructions

2 Technical data
D KUKA article no.
-- Energy supply system assy Art. no. 00--202--507
-- Dress package Art. no. 00--202--487

-- Energy supply system assy Art. no. 00--202--508

-- Dress package Art. no. 00--202--487

-- Energy supply system assy Art. no. 00--202--509

-- Dress package Art. no. 00--202--487

D Wiring diagrams
-- Fig. 3 to Fig. 5

D Control cable, X96 -- X106

-- Configuration 23x 1 mm2 + 2x 1 mm2, shielded
-- Rated voltage 250 V AC/DC
-- Current EN 60204--1
(derating factors must be taken into account)
-- Connection A3 25--pole HAN 25 D connector
with crimp terminals
A6 25--pole HAN 25 D connector
with crimp terminals
The exact connector designation may be noted
from the parts list.
-- Protection rating IP65 in connected state

D Profinet cable, XPN3 -- XPN6

-- Configuration 2x (2x AWG22) shielded
-- Rated voltage 30 V AC/DC
-- Specification Bus cable, Profinet cable
-- Connection Plug--in connections at both ends
A3 Connector, V14 RJ45
A6 Connector, V14 RJ45
The exact connector designation may be noted
from the parts list.
-- Protection rating IP65 in connected state

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2 Technical data (continued)

D Power supply, XPP3 -- XPP6

-- Configuration 5x 1.5 mm2
Overall braided shield
-- Rated voltage 24 V AC/DC
-- Current EN 60204--1
(derating factors must be taken into account)
-- Connection Plug--in connections at both ends
A3 Connector
A6 Connector
The exact connector designation may be noted
from the parts list.
-- Protection rating IP65 in connected state

Notice!
In the case of multi--strand cables, the derating factors specified in EN 60204--1
must be taken into account.

D Air line
-- Hose 1/2”, blue
-- Connection at interface A3 with sealing head, straight, M22x1.5
-- Connection at interface A6 with sealing head, straight, M22x1.5
-- Pressure max. 1.6 MPa (16 bar)

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 Assembly and Operating Instructions

3 Wiring diagrams

Wiring diagram
Connector Pin Wire Strip Wire Connector Pin Signal name
X96 GNYE GNYE X106 Grd. conductor
Control signal

Guide pin
Guide bush

X96 X106

Fig. 3 Wiring diagram, control cable, X96 -- X106

Wiring diagram

Connector Pin Wire Strip Wire Connector Pin Signal name

XPN3 XPN6
1 AWG 22 YE 1 TD+
2 AWG 22 OG 2 TD--
3 AWG 22 WH 3 RD+
6 AWG 22 BU 6 RD--
Housing Housing

Fig. 4 Wiring diagram for Profinet cable, XPN3 -- XPN6

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3 Wiring diagrams (continued)

Wiring diagram

Connector Pin Wire Strip Wire Connector Pin Signal name

XPP3 1 1.5 mm2 1 XPP6 1 L1

2 1.5 mm2 2 2 N1
3 1.5 mm2 3 3 L2
4 1.5 mm2 4 4 N2
5 1.5 mm2 YE 5 PE

Fig. 5 Wiring diagram for power supply, XPP3 -- XPP6

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