kuka kr5sixx spezifikation en

V0.4 20.02.200

Issued: 20.02.2007 Version: 0.4

KUKA Robot Group

Specification

KR 5 sixx R650, R850Specification

© Copyright 2007

KUKA Roboter GmbHZugspitzstraße 140D-86165 AugsburgGermany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the KUKA ROBOT GROUP.

Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work.

We have checked the content of this documentation for conformity with the hardware and software de-scribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guaran-tee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition.

Subject to technical alterations without an effect on the function.

KIM-PS4-DOC

V0.4 22.03.2006 pub de

KR 5 sixx R650, R850

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Contents

1 Product description ......................................................................................... 5

1.1 Overview of the robot system ......................................................................................... 51.2 Description of the KR 5 sixx robot .................................................................................. 51.3 Description of the electrical installations (robot) ............................................................. 71.4 Description of the connecting cables .............................................................................. 11

2 Technical data .................................................................................................. 15

2.1 Basic data ....................................................................................................................... 152.2 Axis data ......................................................................................................................... 162.3 Payloads ......................................................................................................................... 192.4 Loads acting on the foundation ....................................................................................... 212.5 Additional data ................................................................................................................ 22

3 Safety ................................................................................................................ 25

3.1 Designated use ............................................................................................................... 253.2 System planning ............................................................................................................. 253.2.1 EC declaration of conformity and declaration of incorporation .................................. 253.2.2 Installation site ........................................................................................................... 253.2.3 External safeguards ................................................................................................... 263.2.4 Workspace, safety zone and danger zone ................................................................ 263.3 Description ...................................................................................................................... 273.3.1 Category of the safety-oriented circuits ..................................................................... 273.3.2 Stop reactions ............................................................................................................ 273.3.3 Labeling on the robot system ..................................................................................... 283.3.4 Safety information ...................................................................................................... 293.4 Safety features ................................................................................................................ 293.4.1 Overview of the safety features ................................................................................. 293.4.2 ESC safety logic ........................................................................................................ 293.4.3 Operator safety input ................................................................................................. 303.4.4 EMERGENCY STOP button ...................................................................................... 303.4.5 Enabling switches ...................................................................................................... 303.4.6 Jog mode ................................................................................................................... 313.4.7 Mechanical end stops ................................................................................................ 313.4.8 Software limit switches .............................................................................................. 313.5 Personnel ........................................................................................................................ 323.6 Safety measures ............................................................................................................. 333.6.1 General safety measures ........................................................................................... 333.6.2 Transportation ............................................................................................................ 333.6.3 Start-up ...................................................................................................................... 343.6.4 Programming ............................................................................................................. 343.6.5 Automatic mode ......................................................................................................... 35

4 Planning ............................................................................................................ 37

4.1 Fastening to mounting base ........................................................................................... 374.2 Connecting cables and interfaces ................................................................................... 37

5 Transportation .................................................................................................. 39

Contents

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5.1 Transporting the robot .................................................................................................... 39

6 Start-up ............................................................................................................. 43

6.1 Installing a floor-mounted robot ...................................................................................... 43

7 Applied norms and regulations ...................................................................... 45

8 KUKA Service ................................................................................................... 47

8.1 Requesting support ......................................................................................................... 478.2 KUKA Customer Support ................................................................................................ 47

Index .................................................................................................................. 53

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1. Product description

1 Product description

1.1 Overview of the robot system

A robot system consists of the following components:

RobotRobot controllerKCP teach pendantConnecting cablesSoftwareOptions, accessories

1.2 Description of the KR 5 sixx robot

Overview The robot is a 6-axis jointed-arm robot made of cast light alloy. All motor units and current-carrying cables are protected against dirt and moisture beneath screwed-on cover plates.

The robot consists of the following principal components:

In-line wristArmLink armRotating columnBase frameElectrical installations

Fig. 1-1: Example of a robot system

1 Robot 3 Teach pendant (KCP)2 Robot controller 4 Connecting cables

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In-line wrist The robot is fitted with a 3-axis in-line wrist. It is driven by the motors in the arm (axis 4) and in-line wrist. The motor of axis 4 drives the gear unit directly, while axes 5 and 6 are additionally driven by means of a toothed belt. The in-line wrist performs the motions about axes 4, 5 and 6.

There are three 5/2 pulse valves in the in-line wrist that can be used for con-trolling tools. The description and the data of the valve group are given in the section "Technical data" (>>> 2.5 "Additional data" page 22).

The in-line wrist also accommodates the 10-contact circular connector of the wrist I/O cable (>>> Fig. 1-6).

Arm The arm is the link between the in-line wrist and the link arm. It houses the mo-tor of wrist axis 4.

Link arm The link arm is installed between the arm and the rotating column. It houses the motors and gear units of axes 2 and 3. The supply lines of the energy sup-ply system and cable harness for axes 1 to 4 are routed through the link arm. There are 2 variants of link arm available.

Rotating column The rotational motions of axis 1 are performed by the rotating column. This is screwed to the base frame via the gear unit of axis 1 and is driven by a motor in the base frame. The rotating column also houses the backup batteries for backing up the axis data of the position sensing system.

Base frame The base frame is the base of the robot. It constitutes the interface for the con-necting cables between the robot, the controller and the energy supply sys-tem. All connecting cables are accommodated at the rear of the base frame.

Fig. 1-2: Principal components

1 Arm2 In-line wrist3 Link arm4 Rotating column5 Base frame6 Electrical installations

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1.3 Description of the electrical installations (robot)

Overview The electrical installations of the robot consist of:

Cable harnessInterface A 1

Description The electrical installations include all the supply and control cables for the mo-tors of axes 1 to 6. All the connections on the motors are plug-and-socket con-nections. All the cabling is routed internally in the robot in such a way as to minimize wear on the cables. The cable harness is fitted, in places, with flexi-ble tubes.

If cable straps are removed when routing cables, they must be replaced. It must be ensured that cables cannot chafe or come loose during operation.

The connecting cable and the lines of the energy supply system are connected to the robot via the A 1 interface (>>> Fig. 1-3) on the base frame.

Fig. 1-3: Interface A 1

1 Ground conductor connection, M52 Motor/data cable CN223 Compressed air connection AIR1, PT1/44 Compressed air connection AIR2, PT1/45 Wrist I/O cable CN20

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Wiring diagram, motor cable

No brake is provided for the axis 1 motor.

Fig. 1-4: Electrical installations: motor cable

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Wiring diagram, data cable

Fig. 1-5: Electrical installations: data cable

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Wiring diagram, wrist I/O cable

Fig. 1-6: Electrical installations: wrist I/O cable

Fig. 1-7: Wrist I/O cable connectors: CN20 - CN21

Connector CN20 Connector CN21 SignalPin 1 Pin 1 24 V internalPin 2 Pin 2 0 V internalPin 3 Pin 3 $IN9Pin 4 Pin 4 $IN11Pin 5 Pin 5 $IN13Pin 6 Pin 6 $OUT14Pin 7 Pin 7 $OUT16Pin 8 Pin 8 $IN10Pin 9 Pin 9 $IN12

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1.4 Description of the connecting cables

Configuration The connecting cables are used to transfer power and signals between the ro-bot controller and the robot.

The connecting cables include:

Motor/data cableWrist I/O cable (optional)

The motor/data cable has a single shared connector at each end and is con-nected to the A 1 interface of the robot and to the robot controller. The wrist I/O cable also has plug-in connectors. All connecting cables are available in the lengths: 4 m, 6 m and 12 m.

Cable designation The following connecting cables are available:

Pin 10 Pin 10 $IN14Pin 11 N. C. N. C.

Fig. 1-8: Wrist I/O cable connectors: CN20 - valve connector

Connector CN20

Valve connec-tor

Signal Description

Pin 12 Pin 1 0 V internal 0 V internalPin 13 Pin 2 $OUT9 Valve 1 -

position APin 14 Pin 3 $OUT11 Valve 1 -

position BPin 15 Pin 4 $OUT13 Valve 2 -


position BPin 17 Pin 6 $OUT10 Valve 3 -


position B

Connector CN20 Connector CN21 Signal

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The ground conductor is not included in the scope of supply of the robot. The ground conductor is connected using an M5 cable lug.

Bypack connector The bypack connector is available for the in-line wrist interface.

The bypack connector is not included in the scope of supply of the robot.

Connector pin allocation: motor/data cable

The following tables show the connector pin allocation of the motor/data cable with connector X20 on the robot controller and connector CN22 on the robot.

Only those pins actually connected according to the wiring diagram (>>> Fig. 1-4) are assigned.

Cable designationConnector designation: robot controller - robot

KUKA art. no.

Motor/data cable X20 - CN22 00-141-794 (4 m)00-141-800 (6 m)00-141-801 (12 m)

Wrist I/O cable

(optional)

X32 - CN20 00-145-545 (4 m)00-145-546 (6 m)00-145-548 (12 m)

Connector designation KUKA art. no.CN21 00-144-904

Fig. 1-9: Connector X20 - CN22

Connector X20 A

Connector CN22

Signal Description

Pin 1 Pin P +24 V 24 V DCPin 2 Pin W 0V_24 0 VPin 3 Pin U DNC-B3 Brake 3Pin 4 Pin b DNC-B4 Brake 4Pin 5 Pin F DNC-B5 Brake 5Pin 6 Pin L DNC-B3 Brake 6Pin 7 Pin M DN-ENCRX Encoder (RX)Pin 8 Pin V DN-ENCRXR Encoder (RXR)Pin 9 Pin e LED_H SparePin 10 Pin f LED_R SparePin 11 Pin c DNC-B1 Brake 1Pin 12 Pin d DNC-B2 Brake 2Overall shield at both ends on con-nector housing

- - - - - - - -

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Wrist I/O cable connector pin allocation

The following table represents the connector pin allocation of the wrist I/O ca-ble with connector X32 on the robot controller and connector CN20 on the ro-bot.

Connector X20 B

Connector CN22

Signal Description

Pin 1 Pin j 1U Motor A 1 UPin 2 Pin h 2U Motor A 2 UPin 3 Pin H 6U Motor A 6 UPin 4 Pin N DNB-GND GND brakePin 5 Pin r 1V Motor A 1 VPin 6 Pin n 2V Motor A 2 VPin 7 Pin J 6V Motor A 6 VPin 8 Pin G DNC-B_EMG SparePin 9 Pin p 1W Motor A 1 WPin 10 Pin g 2W Motor A 2 WPin 11 Pin R 6W Motor A 6 WPin 12 Pin a 3U Motor A 3 UPin 13 Pin K 4U Motor A 4 UPin 14 Pin E 4V Motor A 4 VPin 15 Pin B 5U Motor A 5 UPin 16 Pin S 3V Motor A 3 VPin 17 Pin A 4W Motor A 4 WPin 18 Pin C 5V Motor A 5 VPin 19 Pin D 5W Motor A 5 WPin 20 Pin T 3W Motor A 3 W- - - - Pin s Ground conduc-

torModule frame

Overall shield at both ends on con-nector housing

- - - - - - - -

Fig. 1-10: Connector X32 - CN20

Connector X32 Connector CN20 SignalPin 1 Pin 13 $OUT9Pin 2 Pin 14 $OUT11Pin 3 Pin 15 $OUT13Pin 4 Pin 16 $OUT15Pin 5 Pin 3 $IN9Pin 6 Pin 4 $IN11

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Assignment of the I/O signals in the IOSYS.INI file:

Pin 7 Pin 5 $IN13Pin 8 Pin 12 0 V internalPin 9 Pin 2 0 V internalPin 10 Pin 11 SparePin 11 N. C. N. C.Pin 12 N. C. N. C.Pin 13 N. C. N. C.Pin 14 Pin 17 $OUT10Pin 15 Pin 18 $OUT12Pin 16 Pin 6 $OUT14Pin 17 Pin 7 $OUT16Pin 18 Pin 8 $IN10Pin 19 Pin 9 $IN12Pin 20 Pin 10 $IN14Pin 21 Pin 1 24 V internalPin 22 Pin 19 24 V internalPin 23 Pin 20 SparePin 24 N. C. N. C.Pin 25 N. C. N. C.

[SRIO]INB0=0 ;$IN[1...8]OUTB0=0 ;$OUT[1...7]INB0=1 ;$IN[9...14]OUTB0=1 ;$OUT[9...16]

Connector X32 Connector CN20 Signal

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2. Technical data

2 Technical data

2.1 Basic data

Basic data

Vibration stress

Ambient temper-ature

Ambient conditions The following ambient conditions must be observed when installing the robot:

Connecting cables Cable lengths: 4 m, 6 m, 12 m

Type KR 5 sixx R650, KR 5 sixx R850Number of axes 6Volume of working envelope

KR 5 sixx R650 1.0 m3

KR 5 sixx R850 2.3 m3

Repeatability (ISO 9283)

KR 5 sixx R650 ±0.02 mm

KR 5 sixx R850 ±0.03 mmWorking envelope ref-erence point

Intersection of axes 4 and 5

Weight KR 5 sixx R650 approx. 28 kg

KR 5 sixx R850 approx. 29 kgPrincipal dynamic loads

See Loads acting on the foundation

Protection classifica-tion of the robot

IP 40, ready for operation, with connecting cables plugged in (according to EN 60529)

Sound level < 75 dB (A) outside the working envelopeMounting position Floor or ceilingSurface finish, paint-work

Plastic: white, paintwork: white, base frame: black

Operation No permanent vibration stress permissible

Brief, one-off: 0.5 gStorage and transpor-tation

Brief, one-off: 3 g

Operation 273 K to 313 K (0 °C to +40 °C)

Relative air humidity ≤ 90%

No condensation permissible.Storage and transpor-tation

263 K to 333 K (-10 °C to +60 °C)

Relative air humidity ≤ 75%

No condensation permissible.

Operation Free from inflammable dust, gases and liq-uidsFree from aggressive and corrosive gases and liquidsFree from flying partsFree from spraying liquidsFree from electromagnetic loads, e.g. from welding equipment or high-frequency con-verters

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The connecting cables consist of the motor/data cable and the wrist I/O cable. The following connector designations and connections are used:

For detailed specifications of the connecting cables, see (>>> 1.4 "Description of the connecting cables" page 11)

2.2 Axis data

The data are valid for floor-mounted KR 5 sixx R650 and KR 5 sixx R850 ro-bots.

Axis data

The direction of motion and the arrangement of the individual axes may be not-ed from the following diagram.

Working envelope The following diagram shows the shape and size of the working envelope.

Cable designation Connector designation

Robot controller - Robot

Motor/data cable X20 - CN22 Harting circular connectorWrist I/O cable X32 - CN20 D-Sub circular connectorGround conductor PE M5 cable lug at each end

AxisRange of motion, software-limited

Speed with rated payload 5 kg

1 +/-170° 375 °/s with R650

250 °/s with R8502 +45° to -190° 300 °/s with R650

250 °/s with R8503 +166° to -119° with R650

+169° to -119° with R850

375 °/s with R650

250 °/s with R8504 +/-190° 410 °/s5 +/-120° 410 °/s6 +/-350 ° 660 °/s

Fig. 2-1: Robot axes

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2. Technical data

Fig. 2-2: Working envelope of the KR 5 sixx R650

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Fig. 2-3: Working envelope of the KR 5 sixx R850

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2. Technical data

2.3 Payloads

Payloads

Load center of gravity P

For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on rotating axis 6. Refer to the payload diagram for the nominal distance.

Payload diagram Permissible mass inertia at the design point (Lx, Ly, Lz) is 0.045 kgm².

Robot KR 5 sixx In-line wrist IW 5Rated payload 5 kgDistance of the load center of gravity Lx 80 mmDistance of the load center of gravity Ly 0 mmDistance of the load center of gravity Lz 150 mmMax. total load 5 kg

Fig. 2-4: Payload on the robot

1 FLANGE coordinate system2 Load center of gravity3 Robot4 Distances LX, LY, LZ of the load center of gravity

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Mounting flange

The mounting flange is depicted (>>> Fig. 2-6) with axes 4 and 5 in the zero position. The symbol Xm indicates the position of the locating element (bush-ing) in the zero position.

Fig. 2-5: Payload diagram

These loading curves correspond to the maximum load capacity. Both values (payload and principal moment of inertia) must be checked in all cases. Ex-ceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Roboter 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 accord-ance with operating and programming instructions of the KUKA System Soft-ware.The mass inertia must be verified using KUKA Load. It is imperative for the load data to be entered in the robot controller!

Mounting flange DIN/ISO 9409-1-A31,5Screw quality 10.9 Screw size M5Grip length 1.5 x nominal diameterDepth of engagement min. 6 mm, max. 8 mmLocating element 5 H7

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2. Technical data

Supplementary load The robot cannot carry supplementary loads.

2.4 Loads acting on the foundation

Loads acting on the foundation

The specified forces and moments already include the payload and the inertia force (weight) of the robot.

Fig. 2-6: Mounting flange

Fig. 2-7: Loads acting on the foundation

Type of load Force/torque/massFv = vertical force Fvmax = 1 000 NFh = horizontal force Fhmax = 1 050 N with R650

Fhmax = 850 N with R850

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2.5 Additional data

Valve assembly The robot has three 5/2-way valves integrated into the in-line wrist. The valve assembly is activated via the internal energy supply system.

Mk = tilting moment Mkmax = 1 000 Nm with R650

Mkmax = 1 100 Nm with R850Mr = torque Mrmax = 1 100 NmTotal mass 33 kg with R650

34 kg with R850Robot mass 28 kg with R650

29 kg with R850 Total load 5 kg

Type of load Force/torque/mass

Designation Limit valuesValve type 5/2 pulse valveOperating pressure, infeed

0.1 to 0.3 MPa

Max. pressure 0.59 MPaSwitching frequency 10 HzOperating temperature 268 K to 323 K (-5 °C to 50 °C)

condensation-freeThreaded union M5 PT1/4Medium Air, oil-freeOperating voltage 24 V ±10%Current 0.5 W, 21 mA

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2. Technical data

Accessories Only accessories authorized and offered by KUKA may be used for this robot. All items of equipment must possess the appropriate certification and declara-tions of conformity.

Fastening threads The fastening holes serve for fastening the covers, axis range limitations or ca-ble harnesses.

Fig. 2-8: Valve diagram

Signal Connector X32

Connector CN20

Valve con-nector

Description

N. C. Pin 8 Pin 12 Pin 1 0 V internal$OUT9 Pin 1 Pin 13 Pin 2 Valve 1 -

position A$OUT10 Pin 14 Pin 17 Pin 6 Valve 3 -


position B$OUT12 Pin 15 Pin 18 Pin 7 Valve 3 -

position B$OUT13 Pin 3 Pin 15 Pin 4 Valve 2 -


position B

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Fig. 2-9: Fastening threads

1 2 holes, M3, 7 mm deep2 2 holes, M4, 16 mm deep3 2 holes, M3, 7 mm deep; distance 104.5 mm4 2 holes, M5, 12 mm deep5 2 holes, M8, 25 mm deep (transportation)

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3. Safety

3 Safety

3.1 Designated use

Use Handling and machining workpieces in dry rooms.

Misuse Any use or applications deviating from the designated use is deemed to be im-permissible misuse; examples of such misuse include:

Transportation of persons and animalsUse as a climbing aidOperation outside the permissible operating parametersUse in potentially explosive environments

3.2 System planning

3.2.1 EC declaration of conformity and declaration of incorporation

EC declaration of conformity

The system integrator must issue a declaration of conformity for the overall system in accordance with Directive 98/37/EC (Machinery Directive). The dec-laration of conformity forms the basis for the CE mark for the system. The ro-bot system must be operated in accordance with the applicable national laws, regulations and standards.

The robot controller has a CE mark in accordance with Directive 89/336/EEC (EMC Directive) and Directive 73/23/EEC (Low Voltage Directive).

Declaration of incor-poration

A declaration of incorporation is provided for the robot system. This declara-tion of incorporation contains the stipulation that the robot system must not be commissioned until it complies with the provisions of 98/37/EC (Machinery Di-rective).

3.2.2 Installation site

Robot When planning the system, it must be ensured that the installation site (floor, wall, ceiling) has the required grade of concrete and load-bearing capacity. The principal loads acting on the mounting base are indicated in the specifica-tions.

Robot controller It is imperative to comply with the minimum clearances of the robot controller from walls, cabinets and other system components.

Important information!The robot system is an integral part of an overall system and may only be op-erated in a CE-compliant system.

Further information is contained in the robot operating instructions.

Further information is contained in the robot controller operating instructions.

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3.2.3 External safeguards

EMERGENCY STOP Additional Emergency Stop devices can be connected via interface X11 or linked together by means of higher-level controllers (e.g. PLC).

The input/output signals and any necessary external power supplies must en-sure a safe state in the case of an Emergency Stop.

Safety fences Requirements on safety fences are:

Safety fences must withstand all forces that are likely to occur in the course of operation, whether from inside or outside the enclosure.Safety fences must not, themselves, constitute a hazard.It is imperative to comply with the minimum clearances from the danger zone.

Safety gates Requirements on safety gates are:

The number of safety gates in the fencing must be kept to a minimum.All safety gates must be safeguarded by means of an operator safety sys-tem (interface X11).Automatic mode must be prevented until all safety gates are closed.In Automatic mode, the safety gate can be mechanically locked by means of a safety system.If the safety gate is opened in Automatic mode, it must trigger an Emer-gency Stop function.If the safety gate is closed, the robot cannot be started immediately in Au-tomatic mode. The message on the control panel must be acknowledged.

Other safety equipment

Other safety equipment must be integrated into the system in accordance with the corresponding standards and regulations.

3.2.4 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards.

The danger zone consists of the workspace and the braking distances of the robot. It must be safeguarded by means of protective barriers to prevent dan-ger to persons or the risk of material damage.


Further information is contained in the corresponding standards and regula-tions.

Further information is contained in the corresponding standards and regula-tions.

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3. Safety

3.3 Description

3.3.1 Category of the safety-oriented circuits

The following circuits correspond to Category 3 in accordance with EN 954-1:

EMERGENCY STOP systemsEnabling switchesOperator safetyOperating modesQualifying inputs

3.3.2 Stop reactions

Stop reactions of the robot system are triggered in response to operator ac-tions or as a reaction to monitoring functions and error messages. The follow-ing table shows the different stop reactions according to the operating mode that has been set.

STOP 0, STOP 1 and STOP 2 are the stop designations defined in EN 60204.

Fig. 3-1: Example of axis range A1

1 Workspace 4 Safety zone2 Robot 5 Braking distance3 Braking distance

Trigger T1, T2 AUT, AUT EXTEMERGENCY STOP Path-oriented braking

(STOP 0)Path-maintaining brak-

ing(STOP 1)

Start key released Ramp-down braking(STOP 2)

-

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3.3.3 Labeling on the robot system

It is forbidden (unmapped Character \x2028)to remove, cover, obliterate, paint over or alter in any other way detracting from their clear visibility

rating plates,warning labels,safety symbols,designation labels andcable markings

on the robot system.

Enabling switch released

Path-oriented braking(STOP 0)

-

Safety gate opened - Path-maintaining brak-ing

(STOP 1)"Drives OFF" key pressed


Operating mode change


Encoder error (DSE-RDC connec-tion broken)

Short-circuit braking

Motion enable can-celed

Ramp-down braking(STOP 2)

STOP key pressed Ramp-down braking(STOP 2)

Controller shut down

Power failure


Trigger T1, T2 AUT, AUT EXT

Stop reaction Drives Brakes SoftwareRamp-down braking (STOP 2)

Remain on. Remain open. Normal ramp which is used for acceleration and deceleration.

Path-main-taining brak-ing (STOP 1)

Switched off after 1 second hardware delay.

Applied after 1 s at latest.

In this time the control-ler brakes the robot on the path using a steep-er stop ramp.

Path-oriented braking (STOP 0)

Switched off immediately.

Applied imme-diately.

The controller attempts to brake the robot on the path with the re-maining energy. If the voltage is not suffi-cient, the robot leaves the programmed path.


Switched off immediately.

Applied imme-diately.

-

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3. Safety

3.3.4 Safety information

Safety information cannot be held against KUKA Roboter GmbH. Even if all safety instructions are followed, this is not a guarantee that the robot system will not cause personal injuries or material damage.

No modifications may be carried out to the robot system without the authori-zation of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the robot sys-tem. The user is liable for any damage these components may cause to the robot system.

3.4 Safety features

3.4.1 Overview of the safety features

The following table indicates the operating modes in which the safety features are active.

3.4.2 ESC safety logic

The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer-aided safety system. It permanently monitors all connected safety-relevant components. In the event of a fault or interruption in the safety circuit, the pow-er supply to the drives is shut off, thus bringing the robot system to a standstill.

The ESC safety logic monitors the following inputs:

Local EMERGENCY STOPExternal EMERGENCY STOPOperator safetyEnablingDrives OFFDrives ONOperating modesQualifying inputs

Safety features T1 T2 AUT AUT EXT

Operator safety - - active active

EMERGENCY STOP button active active active active

Enabling switches active active - -

Reduced velocity active - - -

Jog mode active active - -

Software limit switches active active active active

Danger!In the absence of functional safety equipment, the robot can cause personal injury or material damage. No safety equipment may be dismantled or deac-tivated while the robot is in operation.


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3.4.3 Operator safety input

The operator safety input is used for interlocking fixed guards. Safety equip-ment, such as safety gates, can be connected to the dual-channel input. If nothing is connected to this input, operation in Automatic mode is not possible. Operator safety is not active for test modes T1 and T2.

In the event of a loss of signal during Automatic operation (e.g. safety gate is opened), the drives are deactivated and the robot stops with maximum decel-eration. Once the signal is active at the input again (e.g. safety gate closed and signal acknowledged), Automatic operation can be resumed.

Operator safety can be connected via interface X11.

3.4.4 EMERGENCY STOP button

The EMERGENCY STOP button for the robot system is located on the KCP. If the EMERGENCY STOP button is pressed, the drives are deactivated and the robot stops with maximum deceleration. The EMERGENCY STOP button must be pressed as soon as persons or equipment are endangered. Before operation can be resumed, the EMERGENCY STOP button must be turned to release it and the error message must be acknowledged.

3.4.5 Enabling switches

There are 3 enabling switches installed on the KCP. These 3-position enabling switches can be used to switch on the drives in modes T1 and T2.

In the test modes, the robot can only be moved if one of the enabling switches is held in the central position. If the enabling switch is released or pressed fully down (panic position), the drives are deactivated and the robot stops with max-imum deceleration.


Fig. 3-2: EMERGENCY STOP button on the KCP

1 EMERGENCY STOP button

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3. Safety

3.4.6 Jog mode

In modes T1 and T2, the robot can only be moved in jog mode. For this, an enabling switch and the Start key must be kept held down. If the enabling switch is released or pressed fully down (panic position), the drives are deac-tivated and the robot stops with maximum deceleration. Releasing the Start key causes the robot to be stopped with a STOP 2.

3.4.7 Mechanical end stops

The axis ranges of the main axes A 1 to A 3 are limited by mechanical end stops.

3.4.8 Software limit switches

The axis ranges of all robot axes are limited by means of adjustable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the robot cannot hit the mechanical limit stops.

Fig. 3-3: Enabling switches on the KCP

1 - 3 Enabling switches

Danger!If the robot hits an obstruction, a mechanical end stop or an axis range limi-tation, this can result in material damage to the robot. The KUKA Robot Group must be consulted before the robot is put back into operation (>>> 8 "KUKA Service" page 47). The mechanical end stop or the axis range limitation affected must be exchanged immediately. After a collision at more than 250 mm/s the robot must be exchanged or recommissioning must be carried out by the KUKA Robot Group.

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3.5 Personnel

Betreiber Der Betreiber eines Robotersystems ist für dessen Benutzung verantwortlich. Er muss für einen sicherheitstechnisch einwandfreien Betrieb sorgen und alle Sicherheitsmaßnahmen für das Personal festlegen.

System integrator The robot system is safely integrated into a plant by the system integrator.

The system integrator is responsible for the following tasks:

Installing the robot systemConnecting the robot systemImplementing the required facilitiesIssuing the declaration of conformityAttaching the CE mark

Operator The operator must meet the following preconditions:

The operator must have read and understood the robot system documen-tation, including the safety chapter.The operator must be trained for the work to be carried out.Work on the robot system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and ex-perience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential dangers.

Example The tasks can be distributed as shown in the following table.

Further information is contained in the operating and programming instruc-tions.

Tasks Operator ProgrammerMaintenance technician

Switch robot controller on/off

x x x

Start program x x x

Select program x x x

Select operating mode

x x x

Calibration (tool, base)

x x

Master the robot x x

Configuration x x

Programming x x

Start-up x

Maintenance x

Repair x

Shut-down x

Transportation x

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3. Safety

3.6 Safety measures

3.6.1 General safety measures

The robot system may only be used in technically perfect condition in accord-ance with its designated use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property.

It is important to be prepared for possible movements of the robot even after the robot controller has been switched off and locked. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the robot to sag. If work is to be carried out on a switched-off robot, the robot must first be moved into a position in which it is unable to move on its own, whether the payload is mounted or not. If this is not possible, the robot must be secured by appropriate means.

KCP The KCP must be removed from the system if it is not connected, as the EMERGENCY STOP button is not functional in such a case.

If there are several KCPs in a system, it must be ensured that they are not mixed up.

No mouse or keyboard may be connected to the robot controller.

Faults The following tasks must be carried out in the case of faults to the robot sys-tem:

Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. Indicate the fault by means of a label with a corresponding warning.Keep a record of the faults.Eliminate the fault and carry out a function test.

3.6.2 Transportation

Robot The prescribed transport position of the robot must be observed. Transporta-tion must be carried out in accordance with the robot operating instructions.

Robot controller The robot controller must be transported and installed in an upright position. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller.

Work on the electrical and mechanical equipment of the robot system may only be carried out by specially trained personnel.

Further information is contained in the robot operating instructions.


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3.6.3 Start-up

The robot controller must not be put into operation until the internal tempera-ture of the cabinet has adjusted to the ambient temperature. Otherwise, con-densation could cause damage to electrical components.

Function test It must be ensured that no persons or objects are present within the danger zone of the robot during the function test.

The following must be checked during the function test:

The robot system is installed and connected. There are no foreign bodies or destroyed, loose parts on the robot or in the robot controller.All safety devices and protective measures are complete and fully func-tional.All electrical connections are correct.The peripheral devices are correctly connected.The external environment corresponds to the permissible values indicated in the operating instructions.

Setting It must be ensured that the ratings plate on the robot controller has the same machine data as those entered in the declaration of incorporation. The ma-chine data on the ratings plate of the robot must be entered during start-up.

The robot must not be moved unless the correct machine data are not loaded. Otherwise, damage to property could occur.

3.6.4 Programming

The following safety measures must be carried out during programming:

It must be ensured that no persons are present within the danger zone of the robot during programming.New or modified programs must always be tested first in operating mode T1.If the drives are not required, they must be switched off to prevent the robot from being moved unintentionally.The motors reach temperatures during operation which can cause burns to the skin. Contact should be avoided if at all possible. If necessary, ap-propriate protective equipment must be used.The robot and its tooling must never touch or project beyond the safety fence. Components, tooling and other objects must not become jammed as a re-sult of the robot motion, nor must they lead to short-circuits or be liable to fall off.

The following safety measures must be carried out if programming in the dan-ger zone of the robot:

The robot must only be moved at reduced velocity (max. 250 mm/s). In this way, persons have enough time to move out of the way of hazardous robot motions or to stop the robot.

Further information is contained in the robot operating instructions and in the robot controller operating instructions.


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3. Safety

To prevent other persons from being able to move the robot, the KCP must be kept within reach of the programmer.If two or more persons are working in the system at the same time, they must all use an enabling switch. While the robot is being moved, all per-sons must remain in constant visual contact and have an unrestricted view of the robot system.

3.6.5 Automatic mode

Automatic mode is only permissible in compliance with the following safety measures.

The prescribed safety equipment is present and operational.There are no persons in the system.The defined working procedures are adhered to.

If the robot comes to a standstill for no apparent reason, the danger zone must not be entered until the EMERGENCY STOP function has been triggered.

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4. Planning

4 Planning

4.1 Fastening to mounting base

Description The robot is fastened directly to the mounting base with 4 bolts. A suitable steel construction can be used as the mounting base. The mounting surface must be at least 20 mm thick. It must be ensured that the steel structure is able to withstand safely and permanently the dynamic loads (>>> "Loads acting on the foundation" page 21) to which it is subjected.

In order to fasten the robot to a concrete foundation, a suitable steel plate must be prepared and fastened to the concrete foundation.

The connecting cables to the robot controller must be installed in a cable duct. If required, additional measures must be taken to ensure electromagnetic compatibility (EMC).

Hole pattern The following holes must be used for mounting the robot.

4.2 Connecting cables and interfaces

Description The connecting cables comprise all the cables for transferring energy and sig-nals between the robot and the robot controller. A control cable and 2 com-pressed air lines are also provided for the internal energy supply system.

The robot is connected to the overall ground conductor system via its own ground conductor.

Connector pin allocations and connector designations can be found in the chapter "Description of the connecting cables" (>>> 1.4 "Description of the connecting cables" page 11).

Caution!Installation, connection and start-up of the robot must be carried out in ac-cordance with the applicable national laws and regulations.The robot may only be started up if the applicable regulations have been ob-served.

Fig. 4-1: Hole pattern

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Interface A 1 The diagram (>>> Fig. 1-4) shows the connecting cable interface on the robot and the connections for the energy supply system.

In-line wrist interface The illustration (>>> Fig. 4-3) shows the interface on the in-line wrist.

Fig. 4-2: Interface A 1

1 Ground conductor connection M52 Motor/data cable CN223 Compressed air connection AIR1, PT1/44 Compressed air connection AIR2, PT1/45 Wrist I/O cable CN20

Fig. 4-3: In-line wrist interface

1 Connector CN21, wrist I/O cable2 Valve 1, M53 Compressed air connection AIR2, M54 Valve 2, M55 Valve 3, M5

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5. Transportation

5 Transportation

5.1 Transporting the robot

It must be ensured that the robot is stable while it is being transported. The robot must remain in its transport position until it has been fastened in position. Before the robot is lifted it must be ensured that it is free from obstructions. Re-move all transport safeguards, such as nails and screws, in advance. First re-move any rust or glue on contact surfaces.

Transport position The robot must be in the transport position (>>> Fig. 5-1) before it can be transported. The robot is in the transport position when the axes are in the fol-lowing positions:

Transport dimen-sions

The dimensions for the robot (>>> Fig. 5-2) (1) can be noted from the follow-ing figure. The position of the center of mass (3) and the weight vary according to the specific configuration. The specified dimensions refer to the robot with-out equipment.

For transportation, 2 eyebolts (3) must be inserted.

Type A 1 [º] A 2 [º] A 3 [º] A 4 [º] A 5 [º] A 6 [º]KR 5 sixx 0 -145 +163 +90 +90 0

Fig. 5-1: Transport position

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Transportation The robot can be transported by fork lift truck or using lifting tackle. Ceiling-mounted robots are brought to the installation site already in the correct instal-lation position.

Transportation by fork lift truck

For transport by fork lift truck, the robot must be screwed to a pallet using 4 bolts. A Euro pallet or the pallet used for delivery is suitable for this purpose.

Transportation using lifting tackle

A floor-mounted robot can also be transported using lifting tackle. The robot must be in the transport position (>>> Fig. 5-1). The lifting tackle (1) is at-tached to 2 eyebolts (3) screwed into the base frame (2). Both ropes must be of the same length and must be routed in such a way that the robot is not dam-aged.

Fig. 5-2: Transport dimensions

1 Robot * KR 5 sixx R6502 Center of gravity ** KR 5 sixx R8503 Eyebolts

Caution!Use of unsuitable handling equipment may result in damage to the robot. Only use handling equipment with a sufficient load-bearing capacity. Only transport the robot in the manner specified here.

Fig. 5-3: Transport with a fork lift truck

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5. Transportation

Caution!The robot may tip during transportation. Risk of injury and damage to prop-erty.If the robot is being transported using lifting tackle, special care must be ex-ercised to prevent it from tipping. Additional safeguarding measures must be taken. It is forbidden to pick up the robot in any other way using a crane!

Fig. 5-4: Lifting tackle

1 Lifting tackle2 Eyebolts3 Rotating column

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6. Start-up

6 Start-up

6.1 Installing a floor-mounted robot

Description This description is valid for the installation of floor-mounted robots. The instal-lation and start-up of the robot controller is described in the robot controller op-erating instructions.

Preconditions Holes must be drilled in the mounting base in accordance with the hole pattern.Locating pins must be used.Connecting cables must be installed and routed in the system.The installation site must be free from obstacles and accessible for a crane.

Procedure 1. Check that both locating pins (>>> Fig. 6-1) (5) are undamaged and fitted securely.

2. Clean the mounting surface (4).3. Move the robot into its transport position (>>> Fig. 5-1).4. Screw 2 eyebolts (>>> Fig. 6-1) (2) into the base frame (3) and insert the

lifting tackle (1).The lifting tackle must not damage the robot.

5. Move the robot to the installation site.6. Lower the robot vertically onto the mounting base. Ensure that an entirely

vertical position is maintained in order to prevent damage to the two locat-ing pins (5).

7. Remove the lifting tackle (1).8. Unscrew the 2 eyebolts (2).9. Insert 4 hexagon screws M10x30 ISO4017-12.9 (6) including conical

spring washers and tighten using a torque wrench. Gradually increase the tightening torque to 70 ±14 Nm.

Fig. 6-1: Installing a floor-mounted robot

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10. Connect the ground conductor (>>> Fig. 6-2) (3) using M5 hexagon nuts, washers and a lock washer.

11. Connect the compressed air lines (1, 2).12. Connect the motor/data cable X22 - CN22 (4)13. Connect the wrist I/O cable X32 - CN20 (5)14. Check the position of all cables. They must not be under mechanical strain

nor be able to chafe against other components.15. Adjust the pressure on the pressure regulator if necessary.

16. Mount the tool.

Fig. 6-2: Connecting a floor-mounted robot


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7. Applied norms and regulations

7 Applied norms and regulations

Name Definition Edition73/23/EEC Low Voltage Directive:

Council Directive of 19 February 1973 on the harmonization of the laws of Member States relating to electrical equipment designed for use within certain voltage limits

1993

89/336/EEC EMC Directive:

Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic com-patibility

1993

97/23/EC Pressure Equipment Directive:

Directive of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment

1997

98/37/EC Machinery Directive:

Directive of the European Parliament and of the Council of 22 June 1998 on the approximation of the laws of the Member States relating to machinery

1998

EN 418 Safety of machinery:

EMERGENCY STOP equipment, func-tional aspects; principles for design

1993

EN 563 Safety of machinery:

Temperatures of touchable surfaces - Ergonomics data to establish tempera-ture limit values for hot surfaces

2000

EN 614-1 Safety of machinery:

Ergonomic design principles – Part 1: Terms and general principles

1995

EN 775 Industrial robots:

Safety

1993


Safety-related parts of control systems - Part 1: General principles for design

1997

EN 55011 Industrial, scientific and medical (ISM) radio-frequency equipment – Radio dis-turbance characteristics – Limits and methods of measurement

2003


Electrical equipment of machines - Part 1: General requirements

1998

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EN 61000-4-4 Electromagnetic compatibility (EMC):

Part 4-4: Testing and measurement tech-niques - Electrical fast transient/burst immunity test

2002


Part 4-5: Testing and measurement tech-niques; Surge immunity test

2001


Part 6-2: Generic standards - Immunity for industrial environments

2002


Part 6-4: Generic standards; Emission standard for industrial environments

2002

EN 61800-3 Adjustable speed electrical power drive systems:

Part 3: EMC product standard including specific test methods

2001

EN ISO 12100-1 Safety of machinery:

Basic concepts, general principles for design - Part 1: Basic terminology, meth-odology

2004

EN ISO 12100-2 Safety of machinery:

Basic concepts, general principles for design - Part 2: Technical principles

2004

Name Definition Edition

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8. KUKA Service

8 KUKA Service

8.1 Requesting support

Introduction The KUKA Robot Group documentation offers information on operation and provides assistance with troubleshooting. For further assistance, please con-tact your local KUKA subsidiary.

Information The following information is required for processing a support request:

Model and serial number of the robotModel and serial number of the controllerModel and serial number of the linear unit (if applicable)Version of the KUKA System SoftwareOptional software or modificationsArchive of the softwareApplication usedAny external axes usedDescription of the problem, duration and frequency of the fault

8.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)Luis Angel Huergo 13 20Parque Industrial2400 San Francisco (CBA)ArgentinaTel. +54 3564 421033Fax +54 3564 [email protected]

Australia Marand Precision Engineering Pty. Ltd. (Agency)153 Keys RoadMoorabbinVictoria 31 89AustraliaTel. +61 3 8552-0600Fax +61 3 [email protected]

Faults leading to production downtime are to be reported to the local KUKA subsidiary within one hour of their occurrence.

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Austria KUKA Roboter GmbHVertriebsbüro ÖsterreichRegensburger Strasse 9/14020 LinzAustriaTel. +43 732 784752Fax +43 732 [email protected]

Belgium KUKA Automatisering + Robots N.V.Centrum Zuid 10313530 HouthalenBelgiumTel. +32 11 516160Fax +32 11 [email protected]

Brazil KUKA Roboter do Brasil Ltda.Avenida Franz Liszt, 80Parque Novo MundoJd. GuançãCEP 02151 900 São PauloSP BrazilTel. +55 11 69844900Fax +55 11 [email protected]

Chile Robotec S.A. (Agency)Santiago de ChileChileTel. +56 2 331-5951Fax +56 2 [email protected]

China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.Shanghai Qingpu Industrial ZoneNo. 502 Tianying Rd.201712 ShanghaiP.R. ChinaTel. +86 21 5922-8652Fax +86 21 [email protected]

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8. KUKA Service

France KUKA Automatisme + Robotique SASTechvallée6 Avenue du Parc91140 Villebon s/YvetteFranceTel. +33 1 6931-6600Fax +33 1 [email protected]

Germany KUKA Roboter GmbHBlücherstr. 14486165 AugsburgGermanyTel. +49 821 797-4000Fax +49 821 [email protected]

Hungary KUKA Robotics Hungaria Kft.Fö út 1402335 TaksonyHungaryTel. +36 24 501609Fax +36 24 [email protected]

India KUKA Robotics, Private Limited621 Galleria TowersDLF Phase IV122 002 GurgaonHaryanaIndiaTel. +91 124 [email protected]

Italy KUKA Roboter Italia S.p.A.Via Pavia 9/a - int.610098 Rivoli (TO)ItalyTel. +39 011 959-5013Fax +39 011 [email protected]

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Korea KUKA Robot Automation Korea Co. Ltd.4 Ba 806 Sihwa Ind. ComplexSung-Gok Dong, Ansan CityKyunggi Do425-110KoreaTel. +82 31 496-9937 or -9938Fax +82 31 [email protected]

Malaysia KUKA Robot Automation Sdn BhdSouth East Asia Regional OfficeNo. 24, Jalan TPP 1/10Taman Industri Puchong47100 PuchongSelangorMalaysiaTel. +60 3 8061-0613 or -0614Fax +60 3 [email protected]

Mexico KUKA de Mexico S. de R.L. de C.V.Rio San Joaquin #339, Local 5Colonia Pensil SurC.P. 11490 Mexico D.F.MexicoTel. +52 55 5203-8407Fax +52 55 [email protected]

Norway KUKA Sveiseanlegg + RoboterBryggeveien 92821 GjövikNorwayTel. +47 61 133422Fax +47 61 [email protected]

Portugal KUKA Sistemas de Automatización S.A.Rua do Alto da Guerra n° 50Armazém 042910 011 SetúbalPortugalTel. +351 265 729780Fax +351 265 [email protected]

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8. KUKA Service

Russia KUKA-VAZ EngineeringJushnoje Chaussee, 36 VAZ, PTO445633 TogliattiRussiaTel. +7 8482 391249 or 370564Fax +7 8482 [email protected]

South Africa Jendamark Automation LTD (Agency)76a York RoadNorth End6000 Port ElizabethSouth AfricaTel. +27 41 391 4700Fax +27 41 373 3869www.jendamark.co.za

Spain KUKA Sistemas de Automatización S.A.Pol. IndustrialTorrent de la PasteraCarrer del Bages s/n08800 Vilanova i la Geltrú (Barcelona)SpainTel. +34 93 814-2353Fax +34 93 [email protected]

Sweden KUKA Svetsanläggningar + Robotar ABA. Odhners gata 15421 30 Västra FrölundaSwedenTel. +46 31 7266-200Fax +46 31 [email protected]

Switzerland KUKA Roboter Schweiz AGRiedstr. 78953 DietikonSwitzerlandTel. +41 44 74490-90Fax +41 44 [email protected]

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Taiwan KUKA Robot Automation Taiwan Co. Ltd.136, Section 2, Huanjung E. RoadJungli City, TaoyuanTaiwan 320Tel. +886 3 4371902Fax +886 3 [email protected]

Thailand KUKA Robot Automation (M)SdnBhdThailand Officec/o Maccall System Co. Ltd.49/9-10 Soi Kingkaew 30 Kingkaew RoadTt. Rachatheva, A. BangpliSamutprakarn10540 ThailandTel. +66 2 7502737Fax +66 2 [email protected]

UK KUKA Automation + RoboticsHereward RiseHalesowenB62 8ANUKTel. +44 121 585-0800Fax +44 121 [email protected]

USA KUKA Robotics Corp.22500 Key DriveClinton Township48036 MichiganUSATel. +1 866 8735852Fax +1 586 [email protected]

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Index

Index

Numbers73/23/EEC 25, 4589/336/EEC 25, 4597/23/EC 4598/37/EC 25, 45

AAccessories 5, 23Additional data 22Ambient conditions 15Ambient temperature 15Applied norms and regulations 45Arm 6Automatic mode 35Axis data 16

BBase frame 6Basic data 15Betreiber 32Brake defect 33Braking distance 27Braking, path-maintaining 28Braking, path-oriented 28Bypack connector 12

CCable designation, connecting cables 11Category 3 27CE mark 25Center of mass 39Circuits, safety-oriented 27Configuration, connecting cables 11Connecting cables 5, 11, 15, 37Connecting cables, description 11Connector pin allocation, motor/data cable 12

DDeclaration of incorporation 25Description 27Designated use 25Dimensions, transport 39Drives OFF 29Drives ON 29

EEC declaration of conformity 25Electrical installations 7Electrical installations, description 7EMC Directive 25, 45EMERGENCY STOP 26, 27EMERGENCY STOP button 29, 30EMERGENCY STOP function 35EN 418 45EN 55011 45EN 563 45EN 60204-1 45

EN 61000-4-4 46EN 61000-4-5 46EN 61000-6-2 46EN 61000-6-4 46EN 614-1 45EN 61800-3 46EN 775 45EN 954-1 27, 45EN ISO 12100-1 46EN ISO 12100-2 46Enabling 29Enabling switches 29, 30, 31ESC 29External EMERGENCY STOP 29External safeguards 26

FFastening threads 23Faults 33Floor-mounted robot 43Fork lift truck 40Function test 34

GGeneral safety measures 33Guard interlock 30

HHandling equipment 40

IIn-line wrist 6In-line wrist interface 38Installation site 25Interface A 38Interface A 1 7Interfaces 37

JJog mode 29, 31

KKCP 5, 33KUKA Customer Support 47

LLabeling 28Lifting tackle 40Link arm 6Load bearing capacity of ceiling 25Load bearing capacity of ground 25Load bearing capacity of wall 25Loads acting on the foundation 21Local EMERGENCY STOP 29Locating pin 43Low Voltage Directive 25, 45

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MMachinery Directive 25, 45Mechanical end stops 31Mounting flange 20

OOperating modes 29Operator 32Operator safety 29, 30Operator safety input 30Options 5Overload 33Overview of the robot system 5Overview of the safety features 29

PPanic position 30, 31Path-maintaining 28Path-oriented 28Payload diagram 19Payloads 19Pressure Equipment Directive 45Principal components 5Product description 5Programming 34

RRamp-down braking 28Reduced velocity 29Robot 5, 27Robot controller 5Robot system 5Rotating column 6

SSafety 25Safety features 29Safety fences 26Safety gates 26Safety information 29Safety logic 29Safety zone 26, 27Safety-oriented circuits 27Service, KUKA Roboter 47Setting 34Short-circuit braking 28Software 5Software limit switches 29, 31Start-up 34, 43STOP 0 27STOP 1 27STOP 2 27Stop reactions 27Supplementary load 21Support request 47System integrator 25, 32System planning 25

TTeach pendant 5

Technical data 15Transport position 33, 39Transportation 33, 39

VValve assembly 22Valve group 6Vibration stress 15

WWiring diagrams, data cable 9Wiring diagrams, motor cable 8Wiring diagrams, wrist I/O cable 10Working envelope 16Workspace 26, 27Wrist I/O cable 6Wrist I/O cable, connector pin allocation 13

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