Kuka KR 300-2 PA Assembly Instructions Manual Download

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Robots

KR 300-2 PA, KR 470-2 PA

Assembly Instructions

KUKA Roboter GmbH

Issued: 16.03.2016

Version: MA KR 300 470-2 PA V5

KR 300-2 PA,

KR 470-2 PA

Summary of Contents for KR 300-2 PA

Page 1: ...Robots KR 300 2 PA KR 470 2 PA Assembly Instructions KUKA Roboter GmbH Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 2: ...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 w...

Page 3: ...times for STOP 1 axis 2 30 4 7 3 4 Stopping distances and stopping times for STOP 1 axis 3 32 4 7 4 Stopping distance and stopping times for KR 470 PA 32 4 7 4 1 Stopping distances and stopping times...

Page 4: ...and recommissioning 65 8 1 Mounting base for 175 mm concrete thickness 65 8 2 Mounting base for 200 mm concrete thickness 67 8 3 Installing the machine frame mounting assembly 69 8 4 Installing the r...

Page 5: ...t or remedy emergencies or malfunctions Notices These notices serve to make your work easier or contain references to further information t t These warnings mean that it is certain or highly probable...

Page 6: ...6 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 7: ...als Use as a climbing aid Operation outside the permissible operating parameters Use in potentially explosive environments Use in underground mining 2 s For optimal use of our products we recommend th...

Page 8: ...8 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 9: ...as a 5 axis jointed arm kinematic system The structural components of the robots are made of light alloy and iron castings The axes are driven by AC servomotors A hydropneumatic counterbalancing syst...

Page 10: ...rcumstances End effectors can be attached to the mounting flange of axis 6 The wrist is designed as a hollow shaft wrist and features a through hole with a diameter of 60 mm The assembly also has a ga...

Page 11: ...of the robot It is screwed to the mounting base The interfaces for the electrical installations and the energy supply systems accessory are housed in the base frame The base frame and rotating col umn...

Page 12: ...12 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 13: ...ee Loads acting on the mounting base Protection rating of the robot IP65 ready for operation with connecting cables plugged in according to EN 60529 Protection rating of the wrist IP65 Sound level 72...

Page 14: ...l axes may be not ed from the diagram Fig 4 1 Control cable X21 X31 HAN 3A EMC at both ends Ground conductor equipotential bonding 16 mm2 can be ordered as an option M8 ring cable lug at both ends Cab...

Page 15: ...4 Technical data Working envelope The diagram Fig 4 2 shows the shape and size of the working enve lope The reference point for the working envelope is the intersection of axis 6 with the mounting fl...

Page 16: ...Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA 4 3 Payloads Payloads Fig 4 2 Working envelope KR 300 470 PA Robot KR 300 2 PA KR 470 2 PA Wrist Hollow shaft wrist Hollow shaft...

Page 17: ...d diagram for the nominal distance Payload diagram Rated payload 300 kg 470 kg Distance of the load center of grav ity Lz 300 mm 300 mm Distance of the load center of grav ity Lxy 100 mm 100 mm Permis...

Page 18: ...must be consulted beforehand The values determined here are necessary for planning the robot application For commissioning the robot additional input data are required in accor dance with the operati...

Page 19: ...position Supplementary load The robot can carry supplementary loads on the arm When mounting the sup plementary loads be careful to observe the maximum permissible total load The dimensions and posit...

Page 20: ...s and moments already include the payload and the inertia force weight of the robot Fig 4 6 Supplementary load on arm 1 Axis 3 3 Interference contour on right 2 Fastening thread Fig 4 7 Loads acting o...

Page 21: ...from the following diagram The position of the center of gravity and the weight vary ac cording to the specific configuration The specified dimensions refer to the ro bot without equipment The followi...

Page 22: ...and labels Plates and labels The following plates and labels are attached to the robot They must not be re moved or rendered illegible Illegible plates and labels must be replaced Fig 4 8 Transport d...

Page 23: ...uring operation of the robot surface temperatures may be reached that could result in burn injuries Protective gloves must be worn 3 Secure the axes Before exchanging any motor or counterbalancing sys...

Page 24: ...follow the assembly and operating instructions 6 Transport position Before loosening the bolts of the mounting base the robot must be in the transport position as indicated in the table Risk of toppl...

Page 25: ...A1 A2 and A3 The main axes are the axes with the greatest deflection Superposed axis motions can result in longer stopping distances Stopping distances and stopping times in accordance with DIN EN IS...

Page 26: ...topping distance at least once a year 4 7 2 Terms used Term Description m Mass of the rated load and the supplementary load on the arm Phi Angle of rotation about the corresponding axis This value can...

Page 27: ...1 to axis 3 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 Extension l 100 Program override POV...

Page 28: ...28 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA 4 7 3 2 Stopping distances and stopping times for STOP 1 axis 1 Fig 4 11 Stopping distances for STOP 1 axis 1...

Page 29: ...29 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 4 Technical data Fig 4 12 Stopping times for STOP 1 axis 1...

Page 30: ...30 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA 4 7 3 3 Stopping distances and stopping times for STOP 1 axis 2 Fig 4 13 Stopping distances for STOP 1 axis 2...

Page 31: ...31 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 4 Technical data Fig 4 14 Stopping times for STOP 1 axis 2...

Page 32: ...s 1 to axis 3 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 Extension l 100 Program override POV...

Page 33: ...33 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 4 Technical data 4 7 4 2 Stopping distances and stopping times for STOP 1 axis 1 Fig 4 17 Stopping distances for STOP 1 axis 1...

Page 34: ...34 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA Fig 4 18 Stopping times for STOP 1 axis 1...

Page 35: ...d 16 03 2016 Version MA KR 300 470 2 PA V5 4 Technical data 4 7 4 3 Stopping distances and stopping times for STOP 1 axis 3 Fig 4 19 Stopping distances for STOP 1 axis 3 Fig 4 20 Stopping times for ST...

Page 36: ...36 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA 4 7 4 4 Stopping distances and stopping times for STOP 1 axis 2 Fig 4 21 Stopping distances for STOP 1 axis 2...

Page 37: ...37 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 4 Technical data Fig 4 22 Stopping times for STOP 1 axis 2...

Page 38: ...38 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 39: ...ectified immediately Safety infor mation Safety information cannot be held against KUKA Roboter GmbH Even if all safety instructions are followed this is not a guarantee that the industrial robot will...

Page 40: ...omplete system or The industrial robot together with other machinery constitutes a com plete system or All safety functions and safeguards required for operation in the com plete machine as defined by...

Page 41: ...operating and programming the industrial robot KUKA smartPAD see smartPAD Manipulator The robot arm and the associated electrical installations Safety zone The safety zone is situated outside the dang...

Page 42: ...rds Issuing the declaration of conformity Attaching the CE mark Creating the operating instructions for the complete system Operator The operator must meet the following preconditions The operator mus...

Page 43: ...tation in axes A1 to A3 The adjustable axis range limitation systems restrict the working range to the required minimum This increases personal safety and protection of the system In the case of manip...

Page 44: ...dustrial 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 This...

Page 45: ...ouse An external keyboard and or external mouse may only be used if the following conditions are met Start up or maintenance work is being carried out The drives are switched off There are no persons...

Page 46: ...tion must be carried out in accordance with the operating instructions or assembly instructions of the robot Avoid vibrations and impacts during transportation in order to prevent damage to the manipu...

Page 47: ...anged the manipula tor and the external axes optional may receive incorrect data and can thus cause personal injury or material damage If a system consists of more than one manipulator always connect...

Page 48: ...must be taken into consideration In Manual Reduced Velocity mode T1 If it can be avoided there must be no other persons inside the safeguard ed area If it is necessary for there to be several persons...

Page 49: ...is in progress This sign must remain in place even during temporary interruptions to the work The EMERGENCY STOP devices must remain active If safety functions or safeguards are deactivated during mai...

Page 50: ...carried out by quali fied personnel Hazardous substances The following safety measures must be carried out when handling hazardous substances Avoid prolonged and repeated intensive contact with the s...

Page 51: ...f 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment Only applicable for robots with hydropneumatic counterbal ancing system This directive is valid until...

Page 52: ...KR 300 2 PA KR 470 2 PA EN 61000 6 4 A1 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments 2011 EN 60204 1 A1 Safety of machinery Electrical eq...

Page 53: ...urring during operation The minimum di mensions must be observed Grade of concrete for foundations When producing foundations from concrete observe the load bearing capac ity of the ground and the cou...

Page 54: ...re safely transmitted to the foundation ob serve the dimensions for concrete foundations specified in the following illus tration Fig 6 3 Fig 6 2 Mounting base dimensioned drawing Fig 6 3 Cross sectio...

Page 55: ...ring operation There must be no layers of insulation or screed between the bedplates and the concrete founda tion The minimum dimensions must be observed Grade of concrete for foundations When produci...

Page 56: ...afely transmitted to the foundation ob serve the dimensions for concrete foundations specified in the following illus tration Fig 6 5 Mounting base 200 mm dimensioned drawing 1 Robot contour 2 Bedplat...

Page 57: ...must be ensured that the substructure is able to with stand safely the forces occurring during operation foundation loads The fol lowing diagram contains all the necessary information that must be ob...

Page 58: ...les are used Cable lengths of 7 m 15 m 25 m and 50 m are available The maximum length of the connecting cables must not exceed 50 m Thus if the robot is op erated on a linear unit which has its own en...

Page 59: ...the motor cables and the control cables separately in metal ducts if necessary additional measures must be taken to ensure electromagnet ic compatibility EMC Interface for energy supply systems The r...

Page 60: ...60 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 61: ...afeguards such as nails and screws in advance First remove any rust or glue on contact surfaces Transport position The robot must be in the transport position Fig 7 1 before it can be transported The...

Page 62: ...ruck from the front and rear The fork lift truck must have a minimum payload capacity of 3 5 t Fig 7 2 Transport dimensions 1 Robot 2 Center of gravity 3 Fork slots Use of unsuitable handling equipmen...

Page 63: ...not damaged Installed tools and pieces of equipment can cause undesirable shifts in the center of gravity Fig 7 3 Transportation by fork lift truck The robot may tip during transportation Risk of pers...

Page 64: ...64 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 65: ...ate the forces occurring during operation The minimum di mensions must be observed Grade of concrete for foundations When producing foundations from concrete observe the load bearing capac ity of the...

Page 66: ...re safely transmitted to the foundation ob serve the dimensions for concrete foundations specified in the following illus tration Fig 8 3 Fig 8 2 Mounting base dimensioned drawing Fig 8 3 Cross sectio...

Page 67: ...curring during operation There must be no layers of insulation or screed between the bedplates and the concrete founda tion The minimum dimensions must be observed Grade of concrete for foundations Wh...

Page 68: ...afely transmitted to the foundation ob serve the dimensions for concrete foundations specified in the following illus tration Fig 8 5 Mounting base 200 mm dimensioned drawing 1 Robot contour 2 Bedplat...

Page 69: ...of Pin with fasteners Sword pin with fasteners Hexagon bolts with conical spring washers Preconditions Substructure and mounting surface are prepared as described in Section 6 3 Machine frame mountin...

Page 70: ...an entirely vertical position is maintained in order to prevent damage to the pins 4 Remove the fork lift truck or lifting tackle 5 Insert 8 M24x70 8 8 A2K hexagon bolts together with conical spring...

Page 71: ...lable at the interfaces Standard connecting cable The holding down bolts of the robot on the foundation must be retightened once after 100 operating hours with the specified tightening torque Cable de...

Page 72: ...16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA Fig 8 10 Connecting cable motor cable X20 1 X30 1 Fig 8 11 Wiring diagram motor cable X20 1 X30 1 Fig 8 12 Connecting cable motor cabl...

Page 73: ...73 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 8 Start up and recommissioning Fig 8 13 Wiring diagram motor cable X20 4 X30 4 Fig 8 14 Connecting cable data cable X21 X31...

Page 74: ...nnecting cable wiring diagram data cable X21 X31 Fig 8 16 Connecting cable ground conductor 1 Ground conductor 6 Conical spring washer 2 Hexagon nut 7 Robot 3 Conical spring washer 2x 8 Setscrew 4 Pla...

Page 75: ...ease device can be used for all the motors It is only for use in exceptional circumstances and emergencies e g for freeing people The release device is mounted on the base frame of the manipulator Thi...

Page 76: ...76 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 77: ...observed Section 1 Designation of substance formulation and manufacturer A x Strength class Screw thread 8 8 10 9 12 9 M1 6 0 17 Nm 0 24 Nm 0 28 Nm M2 0 35 Nm 0 48 Nm 0 56 Nm M2 5 0 68 Nm 0 93 Nm 1 10...

Page 78: ...th hazards May irritate eyes and skin Environmental hazards Unlikely to be harmful to aquatic organisms Physical chemical hazards Not classified as dangerous Human health hazards May irritate eyes and...

Page 79: ...n products Decomposition products include various oxides e g carbon oxides Unusual fire explosion haz ards This product is not inherently explosive in accordance with the applicable rules Special fire...

Page 80: ...ntilation is recommended in industry If ventilation is insufficient respiratory protection is useful Hand protection Wear chemical resistant gloves recommended nitrile gloves if prolonged or repeated...

Page 81: ...storage or disposal facilities If necessary dis posal should be entrusted to a recognized waste disposal company Hazardous waste On the basis of the supplier s current state of knowledge this product...

Page 82: ...94 01 Emergency telephone num ber Carechem 44 0 208 762 8322 24 hours Physical chemical hazards Not classified as dangerous Human health hazards Not classified as dangerous Environmental hazards Unlik...

Page 83: ...hemical or carbon dioxide extinguisher or spray Unsuitable extinguishing agents Do NOT use water jets Hazardous decomposition products These products are carbon oxides CO CO2 Unusual fire explosion ha...

Page 84: ...aust ventilation or other engineering controls to keep the relevant airborne concentrations below their respec tive occupational exposure limits All chemicals should be assessed with regard to their r...

Page 85: ...so present due to high prod uct temperature Use filter type AP or comparable standard Skin and body Use of protective clothing is good industrial practice Cotton or polyester cotton overalls only prov...

Page 86: ...sts or fumes result ing from thermal decomposition products occurs Chronic toxicity Carcinogenic effects No component of this product at levels greater than or equal to 0 1 is identified as a carcinog...

Page 87: ...ry Date of issue 29 03 2006 Date of previous issue No previous validation Created by Product Stewardship Group Notes for the reader Indicates information altered since the last version All reasonably...

Page 88: ...ufacturer supplier Kyodo Yushi Co Ltd 2 2 30 Tsujido Kandai Fujisawa shi Kanagawa 251 8588 JAPAN Nabtesco Corporation SERVICE CENTER TSU PLANT 594 Katada cho Tsu shi Mie ken 514 8533 Department for in...

Page 89: ...rsal binders sawdust 6 4 Reference to other sections No hazardous materials are released For information on safe handling see Section 7 Page 90 For information on personal protective equipment see Sec...

Page 90: ...cts Keep separately from oxidizing agents Further specifications con cerning storage conditions Protect from dirt Storage class Classification according to German Ordinance on Industrial Safety and He...

Page 91: ...hrough time must be obtained from the glove manufacturer and observed Eye protection Safety goggles recommended when pouring the product Personal protective equipment Appearance Physical state Color L...

Page 92: ...the product does not produce any effects harmful to health Section 12 Ecological information 12 1 Toxicity Aquatic toxicity No further relevant information available Acute toxicity Primary irritation...

Page 93: ...ethods Section 14 Transport information 14 1 UN number ADR ADN IMDG IATA Not applicable 14 2 UN proper shipping name ADR ADN IMDG IATA Not applicable 14 3 Transport hazard class es ADR ADN IMDG IATA c...

Page 94: ...International Air Transport Association GHS Globally Harmonized System of Classification and Labelling of Chemi cals EINECS European Inventory of Existing Commercial Chemical Substances ELINCS Europe...

Page 95: ...pose of content container at a waste collection point according to local regula tions P501 A Other hazards Assessment to determine PBT and vPvB has not been made Registra tion num ber CAS EC no Substa...

Page 96: ...o not use a water stream as it may spread the fire Special hazards arising from the substance or mixture Not flammable but combustible In the event of a fire liable to generate fumes containing carbon...

Page 97: ...substances occupational exposure limits TRGS 900 issued January 2006 Last amended GMBI 2013 Contains no substances subject to reporting requirements Limitation and monitoring of exposure Appropriate e...

Page 98: ...izing agents Chemical stability The product is stable when used in accordance with the manu facturer s instructions Possibility of hazardous reactions Not known Conditions to be avoided Not known Inco...

Page 99: ...ic properties The product does not have to be classified Test data are not available Reproductive toxicity The product does not have to be classified Test data are not available Single STOT exposure T...

Page 100: ...e 15 02 02 absorbents filter materials including oil filters not otherwise specified wiping cloths protective clothing contaminated by dangerous substances Contaminated packaging is to be disposed of...

Page 101: ...cause long term adverse effects in the aquatic environment H phrases H315 Causes skin irritation H319 Causes severe eye irritation H411 Toxic to aquatic organisms with long lasting effects H412 Harmfu...

Page 102: ...t classified as hazardous according to Direc tive 1999 45 EC and its annexes Sections Section 11 Page 110 and Section 12 Page 110 contain more detailed information on health hazards symptoms and envir...

Page 103: ...Seek medical attention if symptoms occur Protection of first aiders No measures should be taken that involve a risk to personnel or have not been adequately trained Notes to physician Treatment shoul...

Page 104: ...person nel No measures should be taken that involve a risk to personnel or have not been adequately trained Evacuate the environment Refuse access to personnel who are not required or are unpro tecte...

Page 105: ...parameters Safety measures Put on appropriate personal protective equipment Advice on general occupa tional hygiene Eating drinking and smoking should be prohibited in areas where this material is han...

Page 106: ...nt Further information about standards is available from your national organization responsible The final choice of protective equipment will depend on a risk assessment It must always be ensured that...

Page 107: ...conditions and represent how long a glove can be expected to provide effective permeation resistance It is important when following breakthrough time recommendations that actual workplace conditions...

Page 108: ...y to give short duration protec tion and would normally be just for single use applications then disposed of Thicker gloves up to 3 mm or more may be required where there is a mechanical as well as a...

Page 109: ...tible with the following substances oxidizing materi als Appearance Physical state Grease Appearance Color Beige light Odor Not available Odor threshold Not available pH value Not available Melting po...

Page 110: ...lar effects or risks known Symptoms related to the physical chemical and toxicological characteristics Inhalation No specific data Ingestion No specific data Skin contact Adverse symptoms may include...

Page 111: ...Transport hazard class Product Waste disposal methods Recycle the products if at all possible Disposal must be carried out by an authorized waste disposal contractor Hazardous waste Yes European Wast...

Page 112: ...e listed Annex XVII Restrictions on the manufacture plac ing on the market and use of certain dangerous sub stances mixtures and articles Not applicable Other regulations REACH Status The company as i...

Page 113: ...NECS European Inventory of Existing Commercial Chemical Substances ES Exposure Scenario EUH statement CLP specific hazard statement EWC European Waste Catalog GHS Globally Harmonized System of Classif...

Page 114: ...ontained in it is accurate as at the date of issue specified below No warranty or representation express or implied is made as to the accuracy or completeness of the data and information in this data...

Page 115: ...el and serial number of the controller Model and serial number of the energy supply system Designation and version of the system software Designations and versions of other software components or modi...

Page 116: ...Brazil Tel 55 11 4942 8299 Fax 55 11 2201 7883 info kuka roboter com br www kuka roboter com br Chile Robotec S A Agency Santiago de Chile Chile Tel 56 2 331 5951 Fax 56 2 331 5952 robotec robotec cl...

Page 117: ...aon Haryana India Tel 91 124 4635774 Fax 91 124 4635773 info kuka in www kuka in Italy KUKA Roboter Italia S p A Via Pavia 9 a int 6 10098 Rivoli TO Italy Tel 39 011 959 5013 Fax 39 011 959 5141 kuka...

Page 118: ...an Puchong 47100 Puchong Selangor Malaysia Tel 60 03 8063 1792 Fax 60 03 8060 7386 info kuka com my Mexico KUKA de M xico S de R L de C V Progreso 8 Col Centro Industrial Puente de Vigas Tlalnepantla...

Page 119: ...910 011 Set bal Portugal Tel 351 265 729 780 Fax 351 265 729 782 info portugal kukapt com www kuka com Russia KUKA Robotics RUS Werbnaja ul 8A 107143 Moskau Russia Tel 7 495 781 31 20 Fax 7 495 781 31...

Page 120: ...damark co za Taiwan KUKA Robot Automation Taiwan Co Ltd No 249 Pujong Road Jungli City Taoyuan County 320 Taiwan R O C Tel 886 3 4331988 Fax 886 3 4331948 info kuka com tw www kuka com tw Thailand KUK...

Page 121: ...info kuka robotics hu USA KUKA Robotics Corporation 51870 Shelby Parkway Shelby Township 48315 1787 Michigan USA Tel 1 866 873 5852 Fax 1 866 329 5852 info kukarobotics com www kukarobotics com UK KU...

Page 122: ...122 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

Page 123: ...ustrial robot 5 Dynamic Set 53 65 E EC declaration of conformity 40 Electrical installations 9 Electromagnetic compatibility EMC 51 52 EMC Directive 40 50 51 EN 60204 1 A1 52 EN 61000 6 2 51 EN 61000...

Page 124: ...4 Release device option 75 Repair 49 Robot controller 9 39 Rotating column 9 11 RV OIL SB150 lubricating oil 87 S Safety 39 Safety data sheet Castrol Hyspin ZZ 46 hydrau lic oil 81 Safety data sheet L...

Page 125: ...125 125 Issued 16 03 2016 Version MA KR 300 470 2 PA V5 KR 300 2 PA KR 470 2 PA...

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