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8

Maintenance

Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at www.kuka.com or can be obtained directly from
our subsidiaries. 
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.

8.1

Maintenance overview

Description

The maintenance intervals given in the tables are valid for the operating
conditions specified in the technical data (

>>> 

4 "Technical data"

Page 33

). KUKA Deutschland must be consulted in the event of

deviations in working conditions or the use of special functions or applica-
tions.

Further information can be found in the section “Information for plan-
ning” (

>>> 

5.1 "Information for planning" Page 159

).

A general inspection of the manipulator is recommended after 7 years or
upon modifying its use. Please contact KUKA 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
Deutschland GmbH may be used. Non-approved auxiliary substances
and consumables may cause premature wear and failure of assemblies.

Precondition

• The maintenance points must be freely accessible.
• Remove the tools and any additional items of equipment if they im-

pede maintenance work.

WARNING

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
result in death, severe injuries or damage to property.

• While work is being carried out on the robot, it must always be se-

cured by activating the EMERGENCY STOP device.

• If work is carried out on an operational robot that is switched on, the

robot must only be moved at reduced velocity. It must be possible to
stop the robot at any time by activating an EMERGENCY STOP de-
vice. Operation must be limited to what is absolutely necessary.

• Warn all persons concerned before switching on and moving the ro-

bot.

KR IONTEC

MA KR IONTEC V4 | Issued: 11.05.2021

www.kuka.com 

| 189/344

Maintenance

Содержание IONTEC KR 20 R3100

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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