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Kuka IONTEC KR 20 R3100, Assembly Instructions Manual

The Kuka IONTEC KR 20 R3100 is a state-of-the-art robotic arm that offers unmatched precision and efficiency. To ensure seamless installation and operation, make sure to download the Assembly Instructions Manual for free from our website. This manual will guide you through the setup process step by step.

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4.9

Plates and labels

Plates and labels

The following plates and labels (

>>> 

Fig. 4-78

) are attached to the robot.

They must not be removed or rendered illegible. Illegible plates and labels
must be replaced.

Fig. 4-78: Plates and labels, location

Item

Description

1

Secure the axes

Before exchanging any motor, secure the corresponding axis
through safeguarding by suitable means/devices to protect
against possible movement. The axis can move. Risk of crush-
ing!

2

Identification plate

 example

Content according to Machinery Directive.

The QR code contains a link to product information in KUKA
Xpert.

KR IONTEC

126/344 | 

www.kuka.com

MA KR IONTEC V4 | Issued: 11.05.2021

Technical

 data

Summary of Contents for IONTEC KR 20 R3100

Page 1: ...Robots KR IONTEC With F Variants Assembly Instructions Issued 11 05 2021 MA KR IONTEC V4 KUKA Deutschland GmbH...

Page 2: ...case of a replacement or service work We have checked the content of this documentation for conformity with the hardware and soft ware described Nevertheless discrepancies cannot be precluded for whi...

Page 3: ...without drive energy 24 3 4 4 Labeling on the industrial robot 25 3 5 Safety measures 25 3 5 1 General safety measures 25 3 5 2 Transportation 27 3 5 3 Start up and recommissioning 27 3 5 4 Manual mo...

Page 4: ...3 Stopping distances and stopping times STOP 1 A2 132 4 11 2 4 Stopping distances and stopping times STOP 1 A3 134 4 11 3 Stopping distances and times KR 30 R2100 134 4 11 3 1 Stopping distances and...

Page 5: ...3 3 Removing KR IONTEC fork slots 181 7 3 4 Connecting the connecting cables 182 7 3 5 Concluding work 183 7 4 Description of the connecting cables 183 7 5 Description of overtravel protection on axi...

Page 6: ...5 8 9 3 2 Filling gear unit A6 with gear oil 226 8 9 3 3 Concluding work 227 8 10 Cleaning the robot 227 8 10 1 Cleaning 228 8 10 2 Concluding work 228 9 Repair 229 9 1 Exchanging motor A1 229 9 1 1 R...

Page 7: ...t arm 271 9 5 2 7 Concluding work 272 9 5 3 Exchanging motor A6 and in line wrist 272 9 5 3 1 Securing the in line wrist and robot arm 274 9 5 3 2 Removing cover A3 275 9 5 3 3 Removing motor A4 276 9...

Page 8: ...the manipulator without drive energy 322 11 1 1 3 Concluding work 324 11 2 Purge option A 324 11 3 Purge option B 325 11 4 Purge option C 327 11 4 1 Starting up PURGE option C 328 11 4 1 1 Installing...

Page 9: ...ftware Instructions for options and accessories Spare parts overview in KUKA Xpert Each of these sets of instructions is a separate document 1 3 Representation of warnings and notes Safety These warni...

Page 10: ...it may move The axis range must be defined for each axis Stopping distance Stopping distance reaction distance braking distance The stopping distance is part of the danger zone Workspace Area within w...

Page 11: ...d programming the industrial robot KR KUKA robot KR C KUKA Robot Control Robot controller KS Shelf mounted small KUKA smartPAD see smartPAD KUKA smartPAD 2 see smartPAD Manipulator The robot arm and t...

Page 12: ...0 in this document Stop category 1 The manipulator and any external axes optional perform path maintaining braking Operating mode T1 the drives are deactivated as soon as the robot has stopped but no...

Page 13: ...ity 250 mm s permissible W Wall WP Waterproof External axis Motion axis which is not part of the manipulator but is controlled by the robot controller e g KUKA linear unit turn tilt table positioner K...

Page 14: ...KR IONTEC 14 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Introduction...

Page 15: ...the following robot variants KR 20 R3100 KR 30 R2100 KR 50 R2100 KR 50 R2500 KR 50 R2500 F KR 70 R2100 KR 70 R2100 F An industrial robot of this product family comprises the following compo nents Man...

Page 16: ...ine wrist arm The robot is equipped with a three axis in line wrist arm combination This in line wrist arm combination is screwed directly to the link arm of the robot via gear unit A3 End effectors a...

Page 17: ...rical installations consist of ca ble set A1 A3 and cable set A4 A6 All connections are implemented as connectors in order to enable the main axis motors to be exchanged quickly and reliably The elect...

Page 18: ...e g Use as a climbing aid Operation outside the specified operating parameters Operation without the required safety equipment Transportation of persons and animals Outdoor operation Use in a potentia...

Page 19: ...to other material property The industrial robot may only be used in perfect technical condition in ac cordance with its intended use and only by safety conscious persons who are fully aware of the ri...

Page 20: ...tage Directive Declaration of incorporation The partly completed machinery is supplied with a declaration of incorpo ration in accordance with Annex II B of the Machinery Directive 2006 42 EC The asse...

Page 21: ...g device for the robot controller The smartPAD has all the operator control and display functions re quired for operating and programming the industrial robot 2 models exist smartPAD smartPAD 2 In tur...

Page 22: ...KA linear unit turn tilt table positioner 3 2 Personnel The following persons or groups of persons are defined for the industrial robot User Personnel Qualification of personnel Work on the system mus...

Page 23: ...personnel These are people who due to their specialist training knowledge and experience and their familiarization with the relevant standards are able to assess the work to be carried out and detect...

Page 24: ...ted with me chanical axis limitation the workspace must be laid out in such a way that there is no danger to persons or material property even in the absence of mechanical axis limitation If this is n...

Page 25: ...ustrial robot They must not be modified or removed Labeling on the industrial robot consists of Identification plates Warning signs Safety symbols Designation labels Cable markings Rating plates Furth...

Page 26: ...tPAD is used in the overall system it must be ensured that each device is unambiguously assigned to the corresponding industrial robot They must not be interchanged WARNING The operator must ensure th...

Page 27: ...e observed Transportation must be carried out in accordance with the operating in structions or assembly instructions of the robot Avoid vibrations and impacts during transportation in order to preven...

Page 28: ...it until the internal cabinet temperature has adapted to the ambi ent temperature in order to avoid condensation Function test The following tests must be carried out before start up and recommission...

Page 29: ...s or be liable to fall off All setup work must be carried out where possible from outside the safeguarded area If the setup work has to be carried out inside the safeguarded area the following must be...

Page 30: ...adlock to prevent it from being switched on again If it is necessary to carry out work with the robot controller switched on the user must define addi tional safety measures to ensure the safe protect...

Page 31: ...egory I or higher is subject to the Pressure Equipment Directive and CE marked as a component see rating plate of the counterbalancing system The pressure equipment is placed on the market in conjunct...

Page 32: ...ries or damage to property may otherwise result Request up to date safety data sheets from the manufacturers of hazardous substances regularly 3 5 7 Decommissioning storage and disposal The industrial...

Page 33: ...2100 Page 134 KR 50 R2100 Technical data 4 4 Technical data KR 50 R2100 Page 60 Plates and labels 4 9 Plates and labels Page 126 Stopping distances and stopping times 4 11 4 Stopping distances and tim...

Page 34: ...4 2 1 Basic data KR 20 R3100 Basic data KR 20 R3100 Number of axes 6 Number of controlled axes 6 Volume of working envelope 117 9 m Pose repeatability ISO 9283 0 05 mm Weight approx 549 kg Rated payl...

Page 35: ...N 60204 Classification of environmental conditions EN 60721 3 3 Ambient temperature During operation 0 C to 55 C 273 K to 328 K During storage transportation 40 C to 60 C 233 K to 333 K For operation...

Page 36: ...30 s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family Fig 4 1 Direction...

Page 37: ...he working envelope for these variants of this product family The reference point for the working envelope is the intersection of axes 4 and 5 Fig 4 2 KR 20 R3100 working envelope side view KR IONTEC...

Page 38: ...ler if the robot is not operated in the floor mounted position Configura tion of the angles is possible via WorkVisual The inclination angles for an unchanged main working direction of the ro bot Floo...

Page 39: ...ntary load base frame 0 kg Maximum supplementary load base frame 0 kg Rated supplementary load rotating column 0 kg Maximum supplementary load ro tating column 50 kg Rated supplementary load link arm...

Page 40: ...e system The result is a coordinate system named CS B Rotation about the Y axis of CS Result CS C Rotation about the X axis of CS Note A B and C are not shown in the dia gram Mass moments of inertia I...

Page 41: ...required in accordance with the operating and programming instructions of the KUKA System Software The mass inertia must be verified using KUKA Load or KUKA Compose It is imperative for the load data...

Page 42: ...path planning A reduced payload does not necessarily result in lower forces and torques The values are guide values determined by means of trial and simulation and refer to the most heavily loaded mac...

Page 43: ...holes on the arm link arm and rotating column are used for example for fastening the cov ers or external energy supply systems The fastening holes on the in line wrist are exclusively for fastening ho...

Page 44: ...Fig 4 9 KR 20 R3100 fastening of supplementary load arm in line wrist KR IONTEC 44 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 45: ...include the payload and the in ertia force weight of the robot Foundation loads for floor mounting position F v normal 7607 N F v max 10107 N F h normal 4605 N F h max 8475 N M k normal 8986 Nm M k m...

Page 46: ...mounting position F v normal 8833 N F v max 12339 N F h normal 2196 N F h max 5959 N M k normal 11469 Nm M k max 19709 Nm M r normal 4793 Nm M r max 9636 Nm Vertical force F v horizontal force F h ti...

Page 47: ...sideration for Fv 4 3 Technical data KR 30 R2100 4 3 1 Basic data KR 30 R2100 Basic data KR 30 R2100 Number of axes 6 Number of controlled axes 6 Volume of working envelope 36 m Pose repeatability ISO...

Page 48: ...ient temperature During operation 0 C to 55 C 273 K to 328 K During storage transportation 40 C to 60 C 233 K to 333 K For operation at low temperatures it may be necessary to warm up the robot Connec...

Page 49: ...he listed variants of this product family Fig 4 12 Direction of rotation of the axes Mastering positions Mastering position A1 9 A2 90 A3 90 A4 0 A5 50 A6 30 Working envelope The following diagrams sh...

Page 50: ...ed installation The robot can be installed in any position from 0 floor to 180 ceiling The following figure shows the possible limitation of the motion range of axis 1 as a function of the angle of in...

Page 51: ...0 Wall A 0 B 90 C 0 Ceiling A 0 B 0 C 180 CAUTION The inclined installation angles must be individually checked and en tered An incorrectly entered inclined installation angle can lead to un foreseen...

Page 52: ...mum supplementary load link arm 30 kg Rated supplementary load arm 20 kg Maximum supplementary load arm 30 kg Load center of gravity and mass moment of inertia Fig 4 16 Load center of gravity and mass...

Page 53: ...m possible inertia occurs about one of the 3 coordi nate axes More information is contained in the KUKA Load documentation Payload diagram NOTICE This loading curve corresponds to the maximum load cap...

Page 54: ...d case must be verified using KUKA Load or KUKA Compose For fur ther consultation please contact KUKA Support Mounting flange D 100 Robot wrist type ZH70 Mounting flange see drawing Mounting flange ho...

Page 55: ...uide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family The ac tual forces and torques may differ due to internal and external influenc...

Page 56: ...g holes on the arm link arm and rotating column are used for example for fastening the cov ers or external energy supply systems The fastening holes on the in line wrist are exclusively for fastening...

Page 57: ...Fig 4 20 KR 30 50 70 R2100 and KR 50 R2500 fastening of supple mentary load arm in line wrist KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 57 344 Technical data...

Page 58: ...ght of the robot Foundation loads for floor mounting position F v normal 8203 N F v max 11259 N F h normal 4523 N F h max 9133 N M k normal 8952 Nm M k max 17517 Nm M r normal 5141 Nm M r max 9806 Nm...

Page 59: ...um loads must be referred to when dimensioning the founda tions and must be adhered to for safety reasons Failure to observe this can result in personal injury and damage to property The normal loads...

Page 60: ...9 Controller KR C4 Transformation name KR C4 KR50R2100 The manipulator is designed in such a way that in accordance with standard IEC 60529 no water can penetrate into electrical equipment spaces in n...

Page 61: ...ng optional M8 ring cable lug at both ends Cable lengths 7 m 10 m 15 m 20 m 25 m 30 m 35 m 50 m Max cable length 50 m Max number of plug connections 1 For detailed specifications of the connecting cab...

Page 62: ...tion of rotation of the axes Mastering positions Mastering position A1 9 A2 90 A3 90 A4 0 A5 50 A6 30 Working envelope The following diagrams show the shape and size of the working envelope for these...

Page 63: ...ed installation The robot can be installed in any position from 0 floor to 180 ceiling The following figure shows the possible limitation of the motion range of axis 1 as a function of the angle of in...

Page 64: ...C 0 Wall A 0 B 90 C 0 Ceiling A 0 B 0 C 180 CAUTION The inclined installation angles must be individually checked and en tered An incorrectly entered inclined installation angle can lead to un foresee...

Page 65: ...mum supplementary load link arm 30 kg Rated supplementary load arm 20 kg Maximum supplementary load arm 30 kg Load center of gravity and mass moment of inertia Fig 4 27 Load center of gravity and mass...

Page 66: ...m possible inertia occurs about one of the 3 coordi nate axes More information is contained in the KUKA Load documentation Payload diagram NOTICE This loading curve corresponds to the maximum load cap...

Page 67: ...case must be verified using KUKA Load or KUKA Compose For fur ther consultation please contact KUKA Support Mounting flange D 100 Robot wrist type ZH70 Mounting flange see drawing Mounting flange hol...

Page 68: ...uide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family The ac tual forces and torques may differ due to internal and external influenc...

Page 69: ...g holes on the arm link arm and rotating column are used for example for fastening the cov ers or external energy supply systems The fastening holes on the in line wrist are exclusively for fastening...

Page 70: ...Fig 4 31 KR 30 50 70 R2100 and KR 50 R2500 fastening of supple mentary load arm in line wrist KR IONTEC 70 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 71: ...ght of the robot Foundation loads for floor mounting position F v normal 8203 N F v max 11259 N F h normal 4523 N F h max 9133 N M k normal 8952 Nm M k max 17517 Nm M r normal 5141 Nm M r max 9806 Nm...

Page 72: ...um loads must be referred to when dimensioning the founda tions and must be adhered to for safety reasons Failure to observe this can result in personal injury and damage to property The normal loads...

Page 73: ...09 Controller KR C4 Transformation name KR C4 KR50R2500 The manipulator is designed in such a way that in accordance with standard IEC 60529 no water can penetrate into electrical equipment spaces in...

Page 74: ...ng optional M8 ring cable lug at both ends Cable lengths 7 m 10 m 15 m 20 m 25 m 30 m 35 m 50 m Max cable length 50 m Max number of plug connections 1 For detailed specifications of the connecting cab...

Page 75: ...tion of rotation of the axes Mastering positions Mastering position A1 9 A2 90 A3 90 A4 0 A5 50 A6 30 Working envelope The following diagrams show the shape and size of the working envelope for these...

Page 76: ...Fig 4 35 KR 50 R2500 working envelope side view Fig 4 36 KR 50 R2500 working envelope top view KR IONTEC 76 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 77: ...ition Configura tion of the angles is possible via WorkVisual The inclination angles for an unchanged main working direction of the ro bot Floor A 0 B 0 C 0 Wall A 0 B 90 C 0 Ceiling A 0 B 0 C 180 CAU...

Page 78: ...d supplementary load link arm 0 kg Maximum supplementary load link arm 30 kg Rated supplementary load arm 20 kg Maximum supplementary load arm 30 kg Load center of gravity and mass moment of inertia F...

Page 79: ...m possible inertia occurs about one of the 3 coordi nate axes More information is contained in the KUKA Load documentation Payload diagram NOTICE This loading curve corresponds to the maximum load cap...

Page 80: ...case must be verified using KUKA Load or KUKA Compose For fur ther consultation please contact KUKA Support Mounting flange D 100 Robot wrist type ZH70 Mounting flange see drawing Mounting flange hol...

Page 81: ...uide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family The ac tual forces and torques may differ due to internal and external influenc...

Page 82: ...g holes on the arm link arm and rotating column are used for example for fastening the cov ers or external energy supply systems The fastening holes on the in line wrist are exclusively for fastening...

Page 83: ...Fig 4 42 KR 30 50 70 R2100 and KR 50 R2500 fastening of supple mentary load arm in line wrist KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 83 344 Technical data...

Page 84: ...include the payload and the in ertia force weight of the robot Foundation loads for floor mounting position F v normal 8203 N F v max 11259 N F h normal 4523 N F h max 9133 N M k normal 8952 Nm M k m...

Page 85: ...mounting position F v normal 9329 N F v max 10835 N F h normal 2955 N F h max 12215 N M k normal 11841 Nm M k max 18312 Nm M r normal 4815 Nm M r max 9806 Nm Vertical force F v horizontal force F h ti...

Page 86: ...eration for Fv 4 6 Technical data KR 50 R2500 F 4 6 1 Basic data KR 50 R2500 F Basic data KR 50 R2500 F Number of axes 6 Number of controlled axes 6 Volume of working envelope 61 4 m Pose repeatabilit...

Page 87: ...e into electrical equipment spaces in normal operation Water spray and corrosive additives can nevertheless lead to corrosion rust on uncoated parts In this case it is advisable to provide the equipme...

Page 88: ...r of plug connections 1 For detailed specifications of the connecting cables see Description of the connecting cables 4 6 2 Axis data KR 50 R2500 F Axis data Motion range A1 185 A2 175 60 A3 120 170 A...

Page 89: ...A5 50 A6 30 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family The reference point for the working envelope is the inter...

Page 90: ...Fig 4 46 KR 50 R2500 F working envelope side view Fig 4 47 KR 50 R2500 F working envelope top view KR IONTEC 90 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 91: ...tion Configura tion of the angles is possible via WorkVisual The inclination angles for an unchanged main working direction of the ro bot Floor A 0 B 0 C 0 Wall A 0 B 90 C 0 Ceiling A 0 B 0 C 180 CAUT...

Page 92: ...ed supplementary load link arm 0 kg Maximum supplementary load link arm 30 kg Rated supplementary load arm 20 kg Maximum supplementary load arm 30 kg Load center of gravity and mass moment of inertia...

Page 93: ...m possible inertia occurs about one of the 3 coordi nate axes More information is contained in the KUKA Load documentation Payload diagram NOTICE This loading curve corresponds to the maximum load cap...

Page 94: ...ange hole circle 100 mm Screw grade 10 9 Screw size M8 Number of fastening threads 9 Depth of engagement min 14 mm max 20 mm Locating element 8 H7 In line wrist type IW70 The mounting flange is depict...

Page 95: ...values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family The ac tual forces and torques may differ due to internal and external influences on...

Page 96: ...g holes on the arm link arm and rotating column are used for example for fastening the cov ers or external energy supply systems The fastening holes on the in line wrist are exclusively for fastening...

Page 97: ...Fig 4 53 KR 30 50 70 R2100 and KR 50 R2500 fastening of supple mentary load arm in line wrist KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 97 344 Technical data...

Page 98: ...y include the payload and the in ertia force weight of the robot Foundation loads for floor mounting position F v normal 8203 N F v max 11259 N F h normal 4523 N F h max 9133 N M k normal 8952 Nm M k...

Page 99: ...mounting position F v normal 9329 N F v max 10835 N F h normal 2955 N F h max 12215 N M k normal 11841 Nm M k max 18312 Nm M r normal 4815 Nm M r max 9806 Nm Vertical force F v horizontal force F h ti...

Page 100: ...sideration for Fv 4 7 Technical data KR 70 R2100 4 7 1 Basic data KR 70 R2100 Basic data KR 70 R2100 Number of axes 6 Number of controlled axes 6 Volume of working envelope 36 m Pose repeatability ISO...

Page 101: ...ient temperature During operation 0 C to 55 C 273 K to 328 K During storage transportation 40 C to 60 C 233 K to 333 K For operation at low temperatures it may be necessary to warm up the robot Connec...

Page 102: ...e listed variants of this product family Fig 4 56 Direction of rotation of the axes Mastering positions Mastering position A1 9 A2 90 A3 90 A4 0 A5 50 A6 30 Working envelope The following diagrams sho...

Page 103: ...d installation The robot can be installed in any position from 0 floor to 180 ceiling The following figure shows the possible limitation of the motion range of axis 1 as a function of the angle of inc...

Page 104: ...0 Wall A 0 B 90 C 0 Ceiling A 0 B 0 C 180 CAUTION The inclined installation angles must be individually checked and en tered An incorrectly entered inclined installation angle can lead to un foreseen...

Page 105: ...mum supplementary load link arm 30 kg Rated supplementary load arm 20 kg Maximum supplementary load arm 30 kg Load center of gravity and mass moment of inertia Fig 4 60 Load center of gravity and mass...

Page 106: ...possible inertia occurs about one of the 3 coordi nate axes More information is contained in the KUKA Load documentation Payload diagram NOTICE This loading curve corresponds to the maximum load capa...

Page 107: ...case must be verified using KUKA Load or KUKA Compose For fur ther consultation please contact KUKA Support Mounting flange D 100 Robot wrist type ZH70 Mounting flange see drawing Mounting flange hol...

Page 108: ...uide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family The ac tual forces and torques may differ due to internal and external influenc...

Page 109: ...g holes on the arm link arm and rotating column are used for example for fastening the cov ers or external energy supply systems The fastening holes on the in line wrist are exclusively for fastening...

Page 110: ...Fig 4 64 KR 30 50 70 R2100 and KR 50 R2500 fastening of supple mentary load arm in line wrist KR IONTEC 110 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 111: ...ht of the robot Foundation loads for floor mounting position F v normal 8203 N F v max 11259 N F h normal 4523 N F h max 9133 N M k normal 8952 Nm M k max 17517 Nm M r normal 5141 Nm M r max 9806 Nm F...

Page 112: ...um loads must be referred to when dimensioning the founda tions and must be adhered to for safety reasons Failure to observe this can result in personal injury and damage to property The normal loads...

Page 113: ...3 mm x 480 mm Hole pattern mounting surface for kinematic system S400 Permissible angle of inclination Default color Base frame black RAL 9005 Moving parts KUKA Industrial Or ange RAL 2009 Controller...

Page 114: ...liance with the specified ambi ent conditions Ambient conditions Humidity class EN 60204 Classification of environmental conditions EN 60721 3 3 Ambient temperature During operation 0 C to 55 C 273 K...

Page 115: ...0 s Direction of rotation of robot axes The following diagram shows the direction of motion and the arrangement of the individual axes for the listed variants of this product family Fig 4 67 Direction...

Page 116: ...se variants of this product family The reference point for the working envelope is the intersection of axes 4 and 5 Fig 4 68 KR 70 R2100 F working envelope side view Fig 4 69 KR 70 R2100 F working env...

Page 117: ...tion Configura tion of the angles is possible via WorkVisual The inclination angles for an unchanged main working direction of the ro bot Floor A 0 B 0 C 0 Wall A 0 B 90 C 0 Ceiling A 0 B 0 C 180 CAUT...

Page 118: ...ed supplementary load link arm 0 kg Maximum supplementary load link arm 30 kg Rated supplementary load arm 20 kg Maximum supplementary load arm 30 kg Load center of gravity and mass moment of inertia...

Page 119: ...possible inertia occurs about one of the 3 coordi nate axes More information is contained in the KUKA Load documentation Payload diagram NOTICE This loading curve corresponds to the maximum load capa...

Page 120: ...ange hole circle 100 mm Screw grade 10 9 Screw size M8 Number of fastening threads 9 Depth of engagement min 14 mm max 20 mm Locating element 8 H7 In line wrist type IW70 The mounting flange is depict...

Page 121: ...values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family The ac tual forces and torques may differ due to internal and external influences on...

Page 122: ...g holes on the arm link arm and rotating column are used for example for fastening the cov ers or external energy supply systems The fastening holes on the in line wrist are exclusively for fastening...

Page 123: ...Fig 4 75 KR 30 50 70 R2100 and KR 50 R2500 fastening of supple mentary load arm in line wrist KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 123 344 Technical data...

Page 124: ...ght of the robot Foundation loads for floor mounting position F v normal 8203 N F v max 11259 N F h normal 4523 N F h max 9133 N M k normal 8952 Nm M k max 17517 Nm M r normal 5141 Nm M r max 9806 Nm...

Page 125: ...um loads must be referred to when dimensioning the founda tions and must be adhered to for safety reasons Failure to observe this can result in personal injury and damage to property The normal loads...

Page 126: ...on Item Description 1 Secure the axes Before exchanging any motor secure the corresponding axis through safeguarding by suitable means devices to protect against possible movement The axis can move Ri...

Page 127: ...isk of injury 4 Example of identification plate for Foundry Content according to Machinery Directive For Foundry only 5 Work on the robot Before start up transportation or maintenance read and follow...

Page 128: ...H Regulation is in force Detailed REACH information can be found in the product information in KUKA Xpert 4 11 Stopping distances and times 4 11 1 General information Information concerning the data T...

Page 129: ...sured using the robot internal meas uring technique The wear on the brakes varies depending on the operating mode ro bot application and the number of STOP 0 stops triggered It is there fore advisable...

Page 130: ...4 11 2 2 Stopping distances and stopping times STOP 1 A1 Fig 4 79 Stopping distances for STOP 1 axis 1 KR IONTEC 130 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 131: ...Fig 4 80 Stopping times for STOP 1 axis 1 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 131 344 Technical data...

Page 132: ...4 11 2 3 Stopping distances and stopping times STOP 1 A2 Fig 4 81 Stopping distances for STOP 1 axis 2 KR IONTEC 132 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 133: ...Fig 4 82 Stopping times for STOP 1 axis 2 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 133 344 Technical data...

Page 134: ...distances and stopping times STOP 0 A1 to A3 The table shows the stopping distances and stopping times after a STOP 0 category 0 stop is triggered The values refer to the following configuration Exte...

Page 135: ...A3 19 51 Stopping time A1 0 32 s A2 0 31 s A3 0 20 s KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 135 344 Technical data...

Page 136: ...4 11 3 2 Stopping distances and stopping times STOP 1 A1 Fig 4 85 Stopping distances for STOP 1 axis 1 KR IONTEC 136 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 137: ...Fig 4 86 Stopping times for STOP 1 axis 1 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 137 344 Technical data...

Page 138: ...4 11 3 3 Stopping distances and stopping times STOP 1 A2 Fig 4 87 Stopping distances for STOP 1 axis 2 KR IONTEC 138 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 139: ...Fig 4 88 Stopping times for STOP 1 axis 2 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 139 344 Technical data...

Page 140: ...distances and stopping times STOP 0 A1 to A3 The table shows the stopping distances and stopping times after a STOP 0 category 0 stop is triggered The values refer to the following configuration Exte...

Page 141: ...A3 18 25 Stopping time A1 0 29 s A2 0 36 s A3 0 20 s KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 141 344 Technical data...

Page 142: ...4 11 4 2 Stopping distances and stopping times STOP 1 A1 Fig 4 91 Stopping distances for STOP 1 axis 1 KR IONTEC 142 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 143: ...Fig 4 92 Stopping times for STOP 1 axis 1 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 143 344 Technical data...

Page 144: ...4 11 4 3 Stopping distances and stopping times STOP 1 A2 Fig 4 93 Stopping distances for STOP 1 axis 2 KR IONTEC 144 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 145: ...Fig 4 94 Stopping times for STOP 1 axis 2 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 145 344 Technical data...

Page 146: ...Stopping distances and stopping times STOP 0 A1 to A3 The table shows the stopping distances and stopping times after a STOP 0 category 0 stop is triggered The values refer to the following configura...

Page 147: ...A3 19 59 Stopping time A1 0 37 s A2 0 37 s A3 0 22 s KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 147 344 Technical data...

Page 148: ...4 11 5 2 Stopping distances and stopping times STOP 1 A1 Fig 4 97 Stopping distances for STOP 1 axis 1 KR IONTEC 148 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 149: ...Fig 4 98 Stopping times for STOP 1 axis 1 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 149 344 Technical data...

Page 150: ...4 11 5 3 Stopping distances and stopping times STOP 1 A2 Fig 4 99 Stopping distances for STOP 1 axis 2 KR IONTEC 150 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 151: ...Fig 4 100 Stopping times for STOP 1 axis 2 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 151 344 Technical data...

Page 152: ...1 Stopping distances and stopping times STOP 0 A1 to A3 The table shows the stopping distances and stopping times after a STOP 0 category 0 stop is triggered The values refer to the following configur...

Page 153: ...A3 21 66 Stopping time A1 0 38 s A2 0 30 s A3 0 27 s KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 153 344 Technical data...

Page 154: ...4 11 6 2 Stopping distances and stopping times STOP 1 A1 Fig 4 103 Stopping distances for STOP 1 axis 1 KR IONTEC 154 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 155: ...Fig 4 104 Stopping times for STOP 1 axis 1 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 155 344 Technical data...

Page 156: ...4 11 6 3 Stopping distances and stopping times STOP 1 A2 Fig 4 105 Stopping distances for STOP 1 axis 2 KR IONTEC 156 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Technical data...

Page 157: ...Fig 4 106 Stopping times for STOP 1 axis 2 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 157 344 Technical data...

Page 158: ...ping distances and stopping times STOP 1 A3 Fig 4 107 Stopping distances for STOP 1 axis 3 Fig 4 108 Stopping times for STOP 1 axis 3 KR IONTEC 158 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 T...

Page 159: ...onitoring functions come into effect and the robot is automatically switched off This protective function can limit the availability of the robot system 5 2 Mounting base with centering Description Th...

Page 160: ...chni cian Dimensioned drawing The following figure Fig 5 1 provides all the necessary information on the mounting base together with the required foundation data The specified foundation dimensions re...

Page 161: ...ete foundation must be provided with an appropriate edge reinforcement Fig 5 2 Foundation cross section 1 Machine frame mounting 2 Bedplate 3 Resin bonded anchor 4 Concrete foundation A min concrete t...

Page 162: ...of the substructure must be selected so that the stripping safety is ensured e g S355J2G3 WARNING Danger to life and limb due to incorrect mounting If not mounted correctly the kinematic system may to...

Page 163: ...variant Cable lengths of 7 m 10 m 15 m 20 m 25 m 30 m 35 m and 50 m are available as standard The maximum length of the connecting cables must not exceed 50 m The maximum number of connectors is 1 i...

Page 164: ...an cause tripping hazards Injuries or damage to property may result The connecting cables must be installed in such a way e g cable ducts as to prevent tripping hazards Potential tripping hazards must...

Page 165: ...nector pin allocation threaded unions etc is given in separate documen tation KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 165 344 Planning...

Page 166: ...KR IONTEC 166 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Planning...

Page 167: ...cts during transportation in order to prevent damage to the manipulator Transport position The robot must be in the transport position before it can be transported The robot is in the transport positi...

Page 168: ...frame using a fork lift truck WARNING Use of unsuitable handling equipment may result in damage to the robot or injury to persons Only use authorized handling equipment with a suf ficient load bearing...

Page 169: ...ustration so that the robot is not damaged Installed tools and items of equipment can cause undesirable shifts in the center of gravity Items of equipment espe cially energy supply systems must be rem...

Page 170: ...bly 2 Approved M12 lifting accessory rotating column for leg G3 3 Approved M12 lifting accessory base frame for leg G2 4 Approved M12 lifting accessory base frame for leg G1 KR IONTEC 170 344 www kuka...

Page 171: ...f the surface of the concrete foundation is not sufficiently smooth and even the differences must be evened out with a suitable leveling com pound When using resin bonded anchors use only resin cartri...

Page 172: ...are routed to the robot and installed Work safety WARNING When work is performed on this system live parts and unintentional mo tions of the robot positioner or other components can cause injuries an...

Page 173: ...tor or start up techni cian 7 2 1 Installing KR IONTEC fork slots Procedure 1 Mount the fork slots on the rotating column 2 Fasten each fork slot to the rotating column with 2 M16x35 8 8 Allen screws...

Page 174: ...h step 15 If the surface is not sufficiently smooth and even continue with step 10 10 Lift the robot with a fork lift truck 11 Apply sufficient leveling compound to the underside of the bedplates toot...

Page 175: ...ing 1 Resin bonded anchor 2 Locating pin cylindrical 3 M20x60 8 8 A2K hexagon screw with lock washer 8x 4 Bedplate 4x 5 Locating pin flat sided KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com...

Page 176: ...ickness in mm B min distance to edge in mm 180 190 200 190 250 190 7 2 3 Removing KR IONTEC fork slots Procedure 1 Remove the M16x35 8 8 Allen screws and lock washers 2 Remove the Load Lifting Attachm...

Page 177: ...ble connectors it must be en sured that the connectors on the controller and on the robot are locked correctly 4 Check the equipotential bonding in accordance with VDE 0100 and EN 60204 1 Further info...

Page 178: ...n or toppling is impossible the center of gravity must be taken into account 6 1 Transporting the robot Page 167 When rotating the robot care must be taken not to damage the connectors installation ma...

Page 179: ...d on this system live parts and unintentional mo tions of the robot positioner or other components can cause injuries and damage to property If work is carried out on an operable system the main switc...

Page 180: ...i cian 7 3 1 Installing KR IONTEC fork slots Procedure 1 Mount the fork slots on the rotating column 2 Fasten each fork slot to the rotating column with 2 M16x35 8 8 Allen screws including washers 3 B...

Page 181: ...n 8 M20x60 8 8 Allen screws with a torque wrench in diagonally opposite sequence Increase the tightening torque to the specified val ue in several stages Fig 7 7 Machine frame mounting dimensioned dra...

Page 182: ...nical spring washer tightening torque MA 15 0 Nm 3 Connect motor cable X30 and data cable X31 Fig 7 9 When connecting the motor and data cable connectors it must be en sured that the connectors on the...

Page 183: ...eration in accordance with the chapter Start up and recommissioning of the operating and programming in structions for the KUKA System Software KSS 7 4 Description of the connecting cables Configurati...

Page 184: ...arting HAN 16 HP Data cable X21 X31 Harting HAN 3A HAN Q12 Ground conductor equipo tential bonding optional M8 ring cable lug at both ends Standard connecting cable Fig 7 10 Connecting cables overview...

Page 185: ...Fig 7 11 Connecting cable motor cable X20 X30 1 Interface X20 2 Guide pin 3 Guide bush KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 185 344 Start up and recommissioning...

Page 186: ...ting cable wiring diagram data cable X21 X31 Fig 7 14 Connecting cable ground conductor 1 Ground conductor 6 Conical spring washer 2 Hexagon nut 7 Robot 3 Conical spring washer 8 Setscrew M8 KR IONTEC...

Page 187: ...mastering is lost it is necessary to determine which side of the an gle the pin is on before addressing the premastering notch The counter clockwise direction of rotation corresponds to minus and the...

Page 188: ...KR IONTEC 188 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Start up and recommissioning...

Page 189: ...Service for this If the robot is fitted with a KUKA energy supply system optional addi tional maintenance work must be carried out NOTICE Only auxiliary substances and consumables approved by KUKA De...

Page 190: ...ontain maintenance symbols that are not relevant for the maintenance work on this product The maintenance illustrations provide an overview of the relevant maintenance work Oil change Lubricate with g...

Page 191: ...cable set A1 Page 195 Lubricating grease Optitemp RB2 0 03 kg 20 000 h or 5 years at the latest 3 Perform oil change on gear unit A6 8 9 3 Oil change in A6 Page 223 Optigear Synt ALR 150 Initial fill...

Page 192: ...under 12 2 Auxiliary and operating materials used Page 336 The service life of the cable set corresponds to that of the robot provi ded that programs are executed in the normal range If however the p...

Page 193: ...case of damage and or cracks have the cable set exchanged by KU KA Service 20 000 h 2 Grease cable set A1 8 2 Greasing cable set A1 Page 195 Lubricating grease Optitemp RB2 0 03 kg 20 000 h or 5 years...

Page 194: ...isual inspection of visible flexible tubes and check for damage In the case of damage and or cracks have the cable set exchanged by KU KA Service 20 000 h 2 Grease cable set A1 8 2 Greasing cable set...

Page 195: ...Description The following sections describe the procedure for greasing cable set A1 on floor mounted robots For ceiling mounted robots proceed accordingly Equipment The following equipment is required...

Page 196: ...irect contact with cable grease may have an adverse effect on health Wear protective gloves and personal protective equipment The general safety instructions and the safety data sheet must be observed...

Page 197: ...mounted robots For ceiling mounted robots the procedure is to be applied analo gously but with the drain and filler holes reversed Equipment The following equipment is required Designation Article nu...

Page 198: ...result in burns Wear protective gloves WARNING Danger to life and limb due to unintended robot motions Unintended robot motions may result in death severe injuries and dam age to property Secure the r...

Page 199: ...ump to the oil drain tube The oil pump can also be connected directly to the oil drain hole 8 3 2 Filling gear unit A1 with gear oil Page 199 3 Unscrew the magnetic screw plug at the inspection hole 4...

Page 200: ...ption The following sections describe the A2 gear oil change for floor mounted robots For ceiling mounted robots the procedure is to be applied analo gously but with the drain and filler holes reverse...

Page 201: ...ried out immediately after the robot has stopped operating the oil temperature and the surface temperature are liable to be high Touching them may result in burns Wear protective gloves WARNING Danger...

Page 202: ...4 2 Filling gear unit A2 with gear oil Page 202 3 Unscrew the M18x1 5 magnetic screw plug from the inspection hole 4 Fill the amount of oil from below up to the lower edge of the inspec tion hole usin...

Page 203: ...r leaks Run the program in T1 mode and look out for irregularities 8 5 Oil change in A3 Description The following sections describe the A3 gear oil change for floor mounted robots For ceiling mounted...

Page 204: ...tions The robot is in a position in which the oil filler hole and oil drain hole on the gear unit of axis 3 are accessible The gear unit is at operating temperature The arm and in line wrist are in ho...

Page 205: ...h M18x1 5 magnetic screw plug 3 Collection receptacle 8 5 2 Filling gear unit A3 with gear oil Procedure 1 Move the robot to the specified axis position Axis 2 and axis A3 pro duce an angular position...

Page 206: ...ith M18x1 5 magnetic screw plug 3 Oil pump 8 5 3 Concluding work The following concluding work must be carried out Remove oil residue Visual inspection check for leaks Run the program in T1 mode and l...

Page 207: ...e are valid for screws and nuts where no other specifications are giv en Screws of strength class 10 9 and higher as well as screws with test cer tification may only be tightened once with the rated t...

Page 208: ...the oil drain hole and unscrew the M18x1 5 magnetic screw plug 3 Remove the M18x1 5 magnetic screw plug for venting and catch the oil as it drains out 4 Store or dispose of the drained oil in accorda...

Page 209: ...rew plug MA 20 Nm 6 Remove the oil pump 7 Insert and tighten the M18x1 5 magnetic screw plug MA 20 Nm Axis position for checking the fill level on A4 Model Fill level Axis position KR 30 50 70 R2100 K...

Page 210: ...ignation Article number Quantity Optigear ALR 320 KR 30 R2100 KR 50 R2100 KR 50 R2500 KR 50 R2500 F KR 70 R2100 KR 70 R2100 F 12 2 Aux iliary and oper ating materials used Page 336 Initial fill ing qu...

Page 211: ...put it back into opera tion 8 7 1 Draining the gear oil from A5 Procedure 1 Move the arm and in line wrist into horizontal position and turn axis A4 so that the oil drain plug on axis A5 is at the low...

Page 212: ...if damaged 8 7 2 Filling gear unit A5 with gear oil Page 212 3 Connect the oil pump to the oil filler hole 4 Fill the amount of oil up to the lower edge of the inspection hole vent hole and insert and...

Page 213: ...ection check for leaks Run the program in T1 mode and look out for irregularities 8 8 Oil change in A6 Description The following sections describe the A6 gear oil change for floor mounted robots For c...

Page 214: ...and nuts where no other specifications are giv en Screws of strength class 10 9 and higher as well as screws with test cer tification may only be tightened once with the rated tightening torque When t...

Page 215: ...magnetic screw plug 8 8 1 Draining the gear oil from A6 Page 215 3 Remove the upper M10x1 0 magnetic screw plug for venting and catch the oil as it drains out 4 Store or dispose of the drained oil in...

Page 216: ...t and tighten the M10x1 0 magnetic screw plug MA 7 5 Nm 5 Remove the oil pump and insert and tighten the M10x1 0 magnetic screw plug MA 7 5 Nm Axis position for checking the fill level on A6 Model Fil...

Page 217: ...e wrench min 2 Nm to 30 Nm Socket wrench set Collection receptacle Funnel Oil drain tube M18x1 5 0000 265 680 Material The following material is required Designation Article number Quantity Optigear S...

Page 218: ...position Work safety CAUTION High oil and surface temperatures after the robot has stopped op erating If the oil change is carried out immediately after the robot has stopped operating the oil temper...

Page 219: ...the sealing ele ment exchange magnetic screw plugs if damaged 8 9 1 2 Filling gear unit A4 with gear oil Page 219 2 Remove M18x1 5 oil drain tube 3 Insert and tighten the lower M18x1 5 magnetic screw...

Page 220: ...2 Oil change in A5 Description The following sections describe the A5 gear oil change for floor mounted robots For ceiling mounted robots the procedure is to be applied analo gously but with the drain...

Page 221: ...st be determined Only this quan tity of oil may be used when refilling If less than 70 of the specified oil quantity flows out flush the gear unit with the determined quantity of drained oil once then...

Page 222: ...st point 2 Place a receptacle under the oil drain hole and unscrew the M10x1 0 magnetic screw plug 8 9 2 1 Draining the gear oil from A5 Page 222 3 Screw in the M10x1 0 oil drain tube 4 Remove the upp...

Page 223: ...gnetic screw plugs for leaks Fig 8 19 Filling gear unit A5 with gear oil 1 M10x1 0 magnetic screw plug for venting 2 Funnel 3 Oil filling hose 4 M10x1 0 magnetic screw plug for oil drain hole 8 9 2 3...

Page 224: ...y CAUTION The quantity of oil drained depends on the draining time and the oil temperature The refilling quantity is the quantity of oil that was drained from the gear unit at the correct operating te...

Page 225: ...concerned before starting to put it back into opera tion 8 9 3 1 Draining the gear oil from A6 Procedure 1 Move the arm and in line wrist into horizontal position Turn axis A4 so that both M10x1 0 mag...

Page 226: ...he sealing ele ment exchange magnetic screw plugs if damaged 8 9 3 2 Filling gear unit A6 with gear oil Page 226 2 Remove M10x1 0 oil drain tube 3 Insert and tighten the lower M10x1 0 magnetic screw p...

Page 227: ...on The robot must be cleaned in compliance with the instructions given here in order to prevent damage These instructions only refer to the robot Equipment The following equipment is required Designat...

Page 228: ...rry out the clean ing work 4 Clean the robot 5 Fully remove all cleaning agents from the robot 6 Clean any areas of corrosion and reapply corrosion protection 7 Install any safety equipment that has b...

Page 229: ...about this axis Mechanical auxiliary equipment e g support crane or a stable end position e g buffer can be used to secure against motions Equipment The following equipment is required Designation Art...

Page 230: ...es or damage to property may result Switch off the robot system at the main switch and secure it to pre vent unauthorized persons from switching it on again Disconnect the power cable from the supply...

Page 231: ...g motor A1 Procedure 1 If a new motor is to be installed remove any corrosion protection it may have prior to installation 9 1 2 Installing motor A1 Page 231 2 Clean the involute toothing of motor A1...

Page 232: ...s must be taken into con sideration When inserting the connectors turn them until they clearly lock into the coding elements twist proof Fig 9 2 Motor A1 1 Motor A1 2 Connector XP1 3 Connector XM1 4 M...

Page 233: ...ient load bearing capacity Brush SEMD MEMD mastering set 0000 228 936 Material The following material is required Designation Article number Quantity SPP Motor 3 4 kW S0 ME For the following machines...

Page 234: ...e corrosion deformation wear cracks and exchange compo nents if necessary Use only inspected and approved load suspension devices Only use load suspension devices with a sufficient load bearing ca pac...

Page 235: ...he crane hook 2 Raise the rope sling until it is taut Fig 9 3 Securing the link arm 9 2 2 Removing motor A2 Procedure 1 Release and unplug connectors XM2 and XP2 at the right angle con nectors 9 2 2 R...

Page 236: ...2 4 Check the condition of the O ring on the motor shaft exchange if nec essary 5 Position right angle connectors XM2 and XP2 as shown 6 Insert motor A2 taking care not to tilt it Insertion of motor c...

Page 237: ...otor A2 1 M10x25 8 8 A2K Allen screw 2 Motor A2 3 Connector XM2 4 Connector XP2 5 Rotating column 9 2 4 Removing the equipment securing the link arm Procedure 1 Slacken the rope sling and detach from...

Page 238: ...e motor This de scription applies to floor mounted robots If the robot is installed in an in clined or suspended position the procedure is to be applied analogously During removal of the motor the rob...

Page 239: ...cases Within the warranty period If after consultation with KUKA Deutschland GmbH an examination of the defective component by KUKA is required Tightening torques The tightening torques can be found...

Page 240: ...y may result Switch off the robot system at the main switch and secure it to pre vent unauthorized persons from switching it on again Disconnect the power cable from the supply After switching off wai...

Page 241: ...curing robot arm 9 3 2 Removing cover A3 Procedure 1 Unscrew 14 M6x16 8 8 A2K Allen screws from cover A3 Take the cover off the robot arm KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 241 3...

Page 242: ...or A3 Page 242 2 Unscrew 4 M8x22 8 8 A2K Allen screws 3 Release and carefully lift out motor A3 taking care not to tilt it 4 Cover the aperture on gear unit input shaft A3 and protect it against fouli...

Page 243: ...change if nec essary 5 Position right angle connectors XM3 and XP3 as shown 6 Insert motor A3 taking care not to tilt it Insertion of motor can be facilitated by turning it gently about its ro tationa...

Page 244: ...ector XM3 5 Connector XP3 9 3 5 Mounting the cover Procedure 1 Place the cover on the robot arm and fasten in place using 14 M6x16 8 8 A2K Allen screws Tighten the screws in diagonally oppo site seque...

Page 245: ...ew 4 Cover 9 3 6 Removing the equipment securing the in line wrist and robot arm Procedure 1 Slacken the rope sling and detach from the crane 2 Remove rope sling from the in line wrist and robot arm K...

Page 246: ...de T1 9 4 KR IONTEC Foundry 9 4 1 Exchanging motor A1 Description The following instructions describe the exchange of the motor This de scription applies to floor mounted robots If the robot is instal...

Page 247: ...If after consultation with KUKA Deutschland GmbH an examination of the defective component by KUKA is required Tightening torques The tightening torques can be found under 12 1 Tightening torques Page...

Page 248: ...ICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to in creased wear and premature failure of the components During cleaning ensure th...

Page 249: ...t shaft A1 before installation and apply a thin but continuous coat of Microlube GL 261 grease 3 Clean the mounting surface for motor A1 4 Check the condition of the O ring on the motor shaft exchange...

Page 250: ...connectors turn them until they clearly lock into the coding elements twist proof Fig 9 14 Motor A1 Foundry 1 M10x25 8 8 A2K Allen screw 4x 2 Motor A1 3 O ring 23x4 4 Seal 9 4 1 3 Concluding work The...

Page 251: ...terial is required Designation Article number Quantity SPP motor 4 2kW S0 ME Foundry w o adh 0000 387 993 1 Procurement of spare parts Defective components must only be replaced with original spare pa...

Page 252: ...n again Disconnect the power cable from the supply After switching off wait at least 5 minutes and then check to ensure that the robot controller and power cable are deenergized WARNING Risk of crushi...

Page 253: ...Allen screws 3 Release and carefully lift out motor A2 taking care not to tilt it 4 Remove the seal and dispose of it 5 Cover the aperture on gear unit input shaft A2 and protect it against fouling 6...

Page 254: ...ft A2 before installation and apply a thin but continuous coat of Microlube GL 261 grease 3 Clean the mounting surface for motor A2 4 Check the condition of the O ring on the motor shaft exchange if n...

Page 255: ...of the connectors must be taken into con sideration When inserting the connectors turn them until they clearly lock into the coding elements twist proof Fig 9 17 Motor A2 1 M10x25 8 8 A2K Allen screw...

Page 256: ...r A4 Description The following instructions describe the exchange of the motor This de scription applies to floor mounted robots If the robot is installed in an in clined or suspended position the pro...

Page 257: ...together with the defec tive component in the following cases Within the warranty period If after consultation with KUKA Deutschland GmbH an examination of the defective component by KUKA is required...

Page 258: ...wear protective gloves WARNING Risk of crushing during removal and installation of motor When removing or installing the motor there is a risk of injury by crush ing This could result in hand injuries...

Page 259: ...er A3 Procedure 1 Unscrew 14 M6x16 8 8 A2K Allen screws from cover A3 Take the cover off the robot arm Fig 9 20 Cover A3 1 In line wrist 2 Robot arm 3 M6x16 8 8 A2K Allen screw KR IONTEC MA KR IONTEC...

Page 260: ...in line wrist with arm extension a little way out 4 Remove grounding from in line wrist with arm extension Release and unplug connectors XM4 XP4 and XM5 XP5 at the right angle connec tors 5 Remove the...

Page 261: ...ogether with the lock washer and sinuous spring Do not tilt while fitting Fig 9 22 Motor with connecting shaft 1 Connecting shaft according to robot type 2 Lock washer 3 Sinuous spring 4 Motor 5 Inser...

Page 262: ...ne wrist with arm extension to the arm using 18 M6x35 8 8 A2K Allen screws and tighten the screws with a torque wrench in diagonally opposite sequence Increase the tightening tor que to the specified...

Page 263: ...w 4 Cover 9 5 1 6 Removing the equipment securing the in line wrist and robot arm Procedure 1 Slacken the rope sling and detach from the crane 2 Remove rope sling from the in line wrist and robot arm...

Page 264: ...s describe the exchange of the motor This de scription applies to floor mounted robots If the robot is installed in an in clined or suspended position the procedure is to be applied analogously During...

Page 265: ...g cases Within the warranty period If after consultation with KUKA Deutschland GmbH an examination of the defective component by KUKA is required Tightening torques The tightening torques can be found...

Page 266: ...wear protective gloves WARNING Risk of crushing during removal and installation of motor When removing or installing the motor there is a risk of injury by crush ing This could result in hand injuries...

Page 267: ...er A3 Procedure 1 Unscrew 14 M6x16 8 8 A2K Allen screws from cover A3 Take the cover off the robot arm Fig 9 27 Cover A3 1 In line wrist 2 Robot arm 3 M6x16 8 8 A2K Allen screw KR IONTEC MA KR IONTEC...

Page 268: ...in line wrist with arm extension a little way out 4 Remove grounding from in line wrist with arm extension Release and unplug connectors XM4 XP4 and XM5 XP5 at the right angle connec tors 5 Remove the...

Page 269: ...ether with the lock washer and sinuous spring Do not tilt while fitting Fig 9 29 Motor with connecting shaft 1 Connecting shaft according to robot type 2 Lock washer 3 Sinuous spring 4 Motor 5 Insert...

Page 270: ...e in line wrist with arm extension to the arm using 18 Allen screws and tighten the screws with a torque wrench in diagonally op posite sequence Increase the tightening torque to the specified value i...

Page 271: ...w 4 Cover 9 5 2 6 Removing the equipment securing the in line wrist and robot arm Procedure 1 Slacken the rope sling and detach from the crane 2 Remove rope sling from the in line wrist and robot arm...

Page 272: ...A6 and in line wrist Description The following instructions describe the exchange of the motor and in line wrist This description applies to floor mounted robots If the robot is in stalled in an incl...

Page 273: ...the defec tive component in the following cases Within the warranty period If after consultation with KUKA Deutschland GmbH an examination of the defective component by KUKA is required Tightening to...

Page 274: ...from switching it on again Warn all persons concerned before putting the system back into opera tion CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cau...

Page 275: ...er A3 Procedure 1 Unscrew 14 M6x16 8 8 A2K Allen screws from cover A3 Take the cover off the robot arm Fig 9 34 Cover A3 1 In line wrist 2 Robot arm 3 M6x16 8 8 A2K Allen screw KR IONTEC MA KR IONTEC...

Page 276: ...in line wrist with arm extension a little way out 4 Remove grounding from in line wrist with arm extension Release and unplug connectors XM4 XP4 and XM5 XP5 at the right angle connec tors 5 Remove the...

Page 277: ...screw 18 M6x35 8 8 A2K Allen screws between the in line wrist with arm extension and the arm Carefully pull the in line wrist with arm extension a little way out 4 Remove grounding from in line wrist...

Page 278: ...d unplug connectors XM6 and XP6 at the right angle con nectors 4 Release motor A6 and pull it out of the in line wrist being careful not to tilt it 5 Pull the sinuous spring off the motor Fig 9 37 KR...

Page 279: ...wrist and the arm extension and apply a thin but continuous coat of Drei Bond 5204 HV adhesive 7 Plug connectors XM6 and XP6 into the right angle connectors 8 Place the in line wrist on the arm exten...

Page 280: ...robot type 2 Lock washer 3 Sinuous spring 4 Motor 5 Insert 4 M5x14 8 8 A2K Allen screws and tighten with a torque wrench in diagonally opposite sequence Increase the tightening torque to the specifie...

Page 281: ...ce Increase the tightening torque to the specified value in several stages 11 Fasten the motor cable to the first holder at the marked position with a cable strap 12 Plug the plug connection A6 back t...

Page 282: ...que to the specified value in several stages 6 Lift the in line wrist and arm extension to the height of the arm using a sling and crane 7 Pull the cable for motor A6 through the arm 8 Plug connectors...

Page 283: ...8 8 A2K Allen screws and tighten the screws with a torque wrench in diagonally opposite sequence Increase the tightening tor que to the specified value in several stages 11 Fasten the motor cable to t...

Page 284: ...w 4 Cover 9 5 3 11 Removing the equipment securing the in line wrist and robot arm Procedure 1 Slacken the rope sling and detach from the crane 2 Remove rope sling from the in line wrist and robot arm...

Page 285: ...Exchanging the connecting shafts Description The following instructions describe the exchange of connecting shafts A4 and A5 The connecting shafts must always be exchanged as a pair This description...

Page 286: ...following cases Within the warranty period If after consultation with KUKA Deutschland GmbH an examination of the defective component by KUKA is required Tightening torques The tightening torques can...

Page 287: ...wear protective gloves WARNING Risk of crushing during removal and installation of motor When removing or installing the motor there is a risk of injury by crush ing This could result in hand injuries...

Page 288: ...er A3 Procedure 1 Unscrew 14 M6x16 8 8 A2K Allen screws from cover A3 Take the cover off the robot arm Fig 9 46 Cover A3 1 In line wrist 2 Robot arm 3 M6x16 8 8 A2K Allen screw KR IONTEC 288 344 www k...

Page 289: ...in line wrist with arm extension a little way out 4 Remove grounding from in line wrist with arm extension Release and unplug connectors XM4 XP4 and XM5 XP5 at the right angle connec tors 5 Remove the...

Page 290: ...screw 18 M6x35 8 8 A2K Allen screws between the in line wrist with arm extension and the arm Carefully pull the in line wrist with arm extension a little way out 4 Remove grounding from in line wrist...

Page 291: ...nnecting shaft A5 4 Mount motor A5 onto the connecting shaft together with the lock washer and sinuous spring Do not tilt while fitting Fig 9 49 Motor with connecting shaft 1 Connecting shaft accordin...

Page 292: ...ne wrist with arm extension to the arm using 18 Allen screws and tighten the screws with a torque wrench in diagonally op posite sequence Increase the tightening torque to the specified value in sever...

Page 293: ...y opposite sequence Increase the tightening torque to the specified value in several stages 6 Lift the in line wrist and arm extension to the height of the arm using a sling and crane 7 Pull the cable...

Page 294: ...8 8 A2K Allen screws and tighten the screws with a torque wrench in diagonally opposite sequence Increase the tightening tor que to the specified value in several stages 11 Fasten the motor cable to...

Page 295: ...w 4 Cover 9 5 4 8 Removing the equipment securing the in line wrist and robot arm Procedure 1 Slacken the rope sling and detach from the crane 2 Remove rope sling from the in line wrist and robot arm...

Page 296: ...onsist of Cable set Micro RDC box Description The electrical installations consist of the cable set from A1 to A3 with mi cro RDC as well as the cable set from A4 to A6 The cable sets include all the...

Page 297: ...ey are guided without strain or kinking throughout the entire motion range of the robot The following diagram gives an overview of the installation and routing of the cables in Fig 9 56 Fig 9 55 KR 20...

Page 298: ...5 Motor A2 2 Motor A5 6 Motor A1 3 Motor A4 7 Micro RDC box 4 Motor A3 8 Interface A1 Wiring diagrams Designation Connection Figure Wiring diagram A1_KS A3 XM1 XP1 Fig 9 57 Wiring diagram A2_KS A1 A3...

Page 299: ...61 Wiring diagram A6_KS A1 A3 XM6 XP6 Fig 9 62 Wiring diagram A5_KS A4 A6 XM5 1 Fig 9 63 Wiring diagram A6_KS A4 A6 XM6 1 Fig 9 64 Data cable RDC X31 RDC X31 Fig 9 65 Data cable RDC X32 RDC X32 Fig 9...

Page 300: ...Fig 9 58 Wiring diagram axis A2_KS A1 A3 KR IONTEC 300 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Repair...

Page 301: ...Fig 9 59 Wiring diagram axis A3_KS A1 A3 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 301 344 Repair...

Page 302: ...Fig 9 60 Wiring diagram axis A4_KS A1 A3 KR IONTEC 302 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Repair...

Page 303: ...Fig 9 61 Wiring diagram axis A5_KS A1 A3 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 303 344 Repair...

Page 304: ...Fig 9 62 Wiring diagram axis A6_KS A1 A3 KR IONTEC 304 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Repair...

Page 305: ...Fig 9 63 Wiring diagram axis A5_KS A4 A6 KR 30 50 70 R2100 and KR 50 R2500 KR IONTEC MA KR IONTEC V4 Issued 11 05 2021 www kuka com 305 344 Repair...

Page 306: ...Fig 9 64 Wiring diagram axis A6_KS A4 A6 KR 30 50 70 R2100 and KR50 R2500 Fig 9 65 Wiring diagram RDC X31 KR IONTEC 306 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Repair...

Page 307: ...1 Ground conductor interface plate A1 holding plate Cross section 4 mm2 2 Ground conductor interface plate connection plate and RDC box Cross section 4 mm2 3 Ground conductor rotating column arm Cross...

Page 308: ...ion 16 mm2 11 Ground conductor arm wrist main body Cross section 1 5 mm2 Fig 9 68 Wiring diagram protective circuit KR 30 50 70 R2100 and KR 50 R2500 1 Ground conductor interface plate A1 holding plat...

Page 309: ...round conductor wrist main body wrist swivel housing Cross section 1 5 mm2 9 External ground conductor system potential Cross section 16 mm2 10 External ground conductor KRC Cross section 16 mm2 11 Gr...

Page 310: ...KR IONTEC 310 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Repair...

Page 311: ...RNING Danger to life and limb due to unintended robot motions When carrying out the following work the robot must be moved several times between the individual work steps Unintended robot motions may...

Page 312: ...ock washers and pull off the ground conductor 4 Unscrew 8 M20x60 8 8 A2K hexagon bolts 5 Lift the robot vertically off the mounting surface using a crane or fork lift truck and transport it away Take...

Page 313: ...k must be carried out Prepare the robot for storage if the robot is not to be reinstalled 10 2 Storage Description For storage the robot must be removed cleaned and suitably covered Storage location T...

Page 314: ...e parts or parts that might knock against other parts have been removed from the robot Tools and equipment have been removed Work safety WARNING Danger to life and limb due to unintended robot motions...

Page 315: ...re not to damage the 2 locating pins when lifting CAUTION If the robot is caught on the mounting surface it may come free abruptly endangering persons and property The robot must stand loosely on the...

Page 316: ...rs 6 Seal hose connections by suitable means 7 Cover the robot with plastic film and seal it at the base frame against dust If necessary add a desiccant beneath the sheeting 10 2 4 Concluding work No...

Page 317: ...and sealant Drei Bond type 1305 Rotating column arm in line wrist Adhesive and sealant Drei Bond type 1342 Base frame rotating col umn link arm arm in line wrist Adhesive and sealant Drei Bond 5204HV...

Page 318: ...KR IONTEC 318 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Decommissioning storage and disposal...

Page 319: ...and shows the corre sponding direction of motion of the manipulator In order to move the manipulator without drive energy in the event of an accident or malfunction either a sufficient number of rele...

Page 320: ...s Precondition The robot controller is switched off The robot is freely accessible Work safety SAFETY INSTRUCTION The following procedure must be followed exactly WARNING Danger to life and limb due t...

Page 321: ...se device 1 Clip plate 2 TORX 30 key wrench 3 TORX 25 key wrench 4 Hexagon key wrench long 5 mm 5 Release device long 6 M16x25 Allen screw 7 Conical spring washer 3 Attach arrow adhesive labels visibl...

Page 322: ...2 Moving the manipulator without drive energy Procedure 1 The motors for axis 1 and axis 2 are not directly accessible The cover for the axis 3 motor must first be unscrewed Fig 11 4 Cover A3 1 In lin...

Page 323: ...river 3 Push the release device or 12 mm combination wrench onto the cor responding motor and move the axis in the desired direction It is necessary to overcome the resistance of the mechanical motor...

Page 324: ...PURGE option A consists of a service unit and a pressure regulator unit The service unit prepares the com pressed air so that it contains no dirt particles water or chemical contami nation The pressu...

Page 325: ...detection of changes The na ture and scope of the maintenance work depend very much on the specif ic area of application This enables early detection of damage thereby preventing failure of component...

Page 326: ...MPa 0 0 1 0 bar Maintenance If used for its intended purpose the option requires minimal maintenance i e visual inspections are recommended In certain operating conditions regular visual inspections m...

Page 327: ...bar can be connected to the service unit The compressed air preparation system is not suitable for installation in a hygiene area Fig 11 9 PURGE option C Basic data Designation Article number Weight P...

Page 328: ...option can be used to prepare compressed air for cleaning purposes This section describes all work required to put PURGE option C into oper ation Equipment The following equipment is required Designat...

Page 329: ...he pressure regulator together to the plate using 2 M4x6 8 8 Allen screws Fig 11 10 2 Screw this assembly to the bracket with 2 M4x6 8 8 Allen screws 3 Screw the air service unit to the bracket using...

Page 330: ...ir 6 M4x6 Allen screw 2x 7 Plate 8 Pressure regulator 9 Holder for pressure regulator M4x6 Allen screw 2x 10 Robot connection with plastic hose 11 4 1 2 Concluding work The following concluding work m...

Page 331: ...ght PURGE Option D 0000 363 927 approx 2 4 kg Further information about the ambient conditions is contained in the as sembly instructions for the robot and robot controller Operating pressure PURGE ma...

Page 332: ...GE option D into oper ation Equipment The following equipment is required Designation Article number Set of Allen keys 1 5 2 2 5 3 4 5 6 8 10 mm Torque wrench 5 Nm to 50 Nm Material The following mate...

Page 333: ...rews Fig 11 12 2 Position the bracket with assembly on the base frame and insert and tighten 2 M6x16 8 8 hexagon bolts Increase the tightening torque to the specified value in several stages 3 Connect...

Page 334: ...2 Concluding work The following concluding work must be carried out Carry out a test run in T1 mode and look out for irregularities KR IONTEC 334 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 Op...

Page 335: ...0 Nm M4 2 8 Nm 3 8 Nm 4 4 Nm M5 5 6 Nm 7 5 Nm 9 0 Nm M6 9 5 Nm 12 5 Nm 15 0 Nm M8 23 0 Nm 31 0 Nm 36 0 Nm M10 45 0 Nm 60 0 Nm 70 0 Nm M12 78 0 Nm 104 0 Nm 125 0 Nm M14 125 0 Nm 165 0 Nm 195 0 Nm M16...

Page 336: ...7 D 85737 Ismaning Germany Drei Bond type 5204HV 0000 251 505 Adhesive and sealant Drei Bond GmbH Carl Zeiss Ring 17 D 85737 Ismaning Germany Microlube GL 261 0000 135 463 Lubricating grease Kl ber Lu...

Page 337: ...p to date safety data sheets from the manufacturers of auxiliary and operating materials 12 3 Applied standards and regulations Name Edition Definition 2006 42 EC 2006 Machinery Directive Directive 20...

Page 338: ...Content equivalent to ANSI RIA R 15 06 2012 Part 1 EN ISO 12100 2010 Safety of machinery General principles of design risk assessment and risk reduction EN ISO 13849 1 2015 Safety of machinery Safety...

Page 339: ...rmation which is rele vant in many cases Model and serial number of the kinematic system e g the manip ulator Model and serial number of the controller Model and serial number of the energy supply sys...

Page 340: ...KR IONTEC 340 344 www kuka com MA KR IONTEC V4 Issued 11 05 2021 KUKA Service...

Page 341: ...ty 20 Declaration of incorporation 19 20 Decommissioning 32 311 Description of the robot system 15 Dimensions transport 167 Dimensions transportation 167 Directives 337 Disclaimer 19 Disposal 32 311 3...

Page 342: ...ng 161 Machine frame mounting installing 180 Machinery Directive 20 337 Main axes 128 Maintenance 30 189 Maintenance symbols 190 192 Maintenance table KR IONTEC KR 20 R3100 190 Maintenance table KR IO...

Page 343: ...ling quantity 218 221 224 Regulations 337 Release device 24 319 Start up 319 Removing 176 181 Repair 30 229 Robot controller 15 19 Robot with mounting base installation 173 Rotating column 16 17 S Saf...

Page 344: ...rques 335 Training 9 189 229 Transport position 167 Transportation 27 167 Transportation by fork lift truck 168 Transportation of robot 167 Transportation with lifting tackle optional 169 Turn tilt ta...

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