KUKA Robot Group

Specification

KR 5 sixx R650, R850

Specification

Issued: 20.02.2007 Version: 0.4

V0.4 20.02.200

KR 5 sixx R650, R850

Copyright 2007
KUKA Roboter GmbH
Zugspitzstrae 140
D-86165 Augsburg
Germany
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 described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and
necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS4-DOC

V0.4
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Contents

Contents
1

Product description .........................................................................................

1.1

Overview of the robot system .........................................................................................

1.2

Description of the KR 5 sixx robot ..................................................................................

1.3

Description of the electrical installations (robot) .............................................................

1.4

Description of the connecting cables ..............................................................................

11

Technical data ..................................................................................................

15

2.1

Basic data .......................................................................................................................

15

2.2

Axis data .........................................................................................................................

16

2.3

Payloads .........................................................................................................................

19

2.4

Loads acting on the foundation .......................................................................................

21

2.5

Additional data ................................................................................................................

22

Safety ................................................................................................................

25

3.1

Designated use ...............................................................................................................

25

3.2

System planning .............................................................................................................

25

3.2.1

EC declaration of conformity and declaration of incorporation ..................................

25

3.2.2

Installation site ...........................................................................................................

25

3.2.3

External safeguards ...................................................................................................

26

3.2.4

Workspace, safety zone and danger zone ................................................................

26

3.3

Description ......................................................................................................................

27

3.3.1

Category of the safety-oriented circuits .....................................................................

27

3.3.2

Stop reactions ............................................................................................................

27

3.3.3

Labeling on the robot system .....................................................................................

28

3.3.4

Safety information ......................................................................................................

29

Safety features ................................................................................................................

29

3.4.1

Overview of the safety features .................................................................................

29

3.4.2

ESC safety logic ........................................................................................................

29

3.4.3

Operator safety input .................................................................................................

30

3.4.4

EMERGENCY STOP button ......................................................................................

30

3.4.5

Enabling switches ......................................................................................................

30

3.4.6

Jog mode ...................................................................................................................

31

3.4.7

Mechanical end stops ................................................................................................

31

3.4.8

Software limit switches ..............................................................................................

31

3.5

Personnel ........................................................................................................................

32

3.6

Safety measures .............................................................................................................

33

3.4

3.6.1

General safety measures ...........................................................................................

33

3.6.2

Transportation ............................................................................................................

33

3.6.3

Start-up ......................................................................................................................

34

3.6.4

Programming .............................................................................................................

34

3.6.5

Automatic mode .........................................................................................................

35

Planning ............................................................................................................

37

4.1

Fastening to mounting base ...........................................................................................

37

4.2

Connecting cables and interfaces ...................................................................................

37

Transportation ..................................................................................................

39

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KR 5 sixx R650, R850

5.1

Transporting the robot ....................................................................................................

39

Start-up .............................................................................................................

43

6.1

Installing a floor-mounted robot ......................................................................................

43

Applied norms and regulations ......................................................................

45

KUKA Service ...................................................................................................

47

8.1

Requesting support .........................................................................................................

47

8.2

KUKA Customer Support ................................................................................................

47

Index ..................................................................................................................

53

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1. Product description

Product description

1.1

Overview of the robot system

A robot system consists of the following components:

Robot

Robot controller

KCP teach pendant

Connecting cables

Software

Options, accessories

Fig. 1-1: Example of a robot system

1
2

1.2

Robot
Robot controller

3
4

Teach pendant (KCP)

Connecting cables

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:

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In-line wrist

Arm

Link arm

Rotating column

Base frame

Electrical installations

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KR 5 sixx R650, R850

Fig. 1-2: Principal components

1
2
3
4
5
6
In-line wrist

Arm
In-line wrist
Link arm
Rotating column
Base frame
Electrical installations

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 controlling 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 motor 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 supply 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 connecting cables between the robot, the controller and the energy supply system. All connecting cables are accommodated at the rear of the base frame.

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1. Product description

1.3

Description of the electrical installations (robot)

Overview

Description

The electrical installations of the robot consist of:

Cable harness

Interface A 1

The electrical installations include all the supply and control cables for the motors of axes 1 to 6. All the connections on the motors are plug-and-socket connections. 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 flexible 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
2
3
4
5

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Ground conductor connection, M5

Motor/data cable CN22
Compressed air connection AIR1, PT1/4
Compressed air connection AIR2, PT1/4
Wrist I/O cable CN20

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KR 5 sixx R650, R850

Wiring diagram,
motor cable

Fig. 1-4: Electrical installations: motor cable

No brake is provided for the axis 1 motor.

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1. Product description

Wiring diagram, data

cable

Fig. 1-5: Electrical installations: data cable

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KR 5 sixx R650, R850

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
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9

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Connector CN21
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9

Signal
24 V internal
0 V internal
$IN9
$IN11
$IN13
$OUT14
$OUT16
$IN10
$IN12

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1. Product description

Connector CN20
Pin 10
Pin 11

Connector CN21
Pin 10
N. C.

Signal
$IN14
N. C.

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

1.4

Connector
CN20
Pin 12
Pin 13

Valve connector
Pin 1
Pin 2

Signal

Description

0 V internal
$OUT9

Pin 14

Pin 3

$OUT11

Pin 15

Pin 4

$OUT13

Pin 16

Pin 5

$OUT15

Pin 17

Pin 6

$OUT10

Pin 18

Pin 7

$OUT12

0 V internal
Valve 1 position A
Valve 1 position B
Valve 2 position A
Valve 2 position B
Valve 3 position A
Valve 3 position B

Description of the connecting cables

Configuration

The connecting cables are used to transfer power and signals between the robot controller and the robot.
The connecting cables include:

Motor/data cable

Wrist I/O cable (optional)

The motor/data cable has a single shared connector at each end and is connected 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

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The following connecting cables are available:

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KR 5 sixx R650, R850

Cable designation

Connector
designation: robot
controller - robot

Motor/data cable

X20 - CN22

Wrist I/O cable

X32 - CN20

KUKA art. no.

00-141-794 (4 m)
00-141-800 (6 m)
00-141-801 (12 m)
00-145-545 (4 m)
00-145-546 (6 m)
00-145-548 (12 m)

(optional)

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.

Connector designation

KUKA art. no.

CN21

00-144-904

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.

Fig. 1-9: Connector X20 - CN22

Connector X20
A

Connector
CN22

Pin 1
Pin P
Pin 2
Pin W
Pin 3
Pin U
Pin 4
Pin b
Pin 5
Pin F
Pin 6
Pin L
Pin 7
Pin M
Pin 8
Pin V
Pin 9
Pin e
Pin 10
Pin f
Pin 11
Pin c
Pin 12
Pin d
Overall shield at both ends on connector housing

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Signal

Description

+24 V
0V_24
DNC-B3
DNC-B4
DNC-B5
DNC-B3
DN-ENCRX
DN-ENCRXR
LED_H
LED_R
DNC-B1
DNC-B2
----

24 V DC
0V
Brake 3
Brake 4
Brake 5
Brake 6
Encoder (RX)
Encoder (RXR)
Spare
Spare
Brake 1
Brake 2
----

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1. Product description

Connector X20
B

Connector
CN22

Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
Pin 15
Pin 16
Pin 17
Pin 18
Pin 19
Pin 20
----

Pin j
Pin h
Pin H
Pin N
Pin r
Pin n
Pin J
Pin G
Pin p
Pin g
Pin R
Pin a
Pin K
Pin E
Pin B
Pin S
Pin A
Pin C
Pin D
Pin T
Pin s

Overall shield at both ends on connector housing

Wrist I/O cable
connector pin
allocation

Signal

Description

1U
2U
6U
DNB-GND
1V
2V
6V
DNC-B_EMG
1W
2W
6W
3U
4U
4V
5U
3V
4W
5V
5W
3W
Ground conductor
----

Motor A 1 U
Motor A 2 U
Motor A 6 U
GND brake
Motor A 1 V
Motor A 2 V
Motor A 6 V
Spare
Motor A 1 W
Motor A 2 W
Motor A 6 W
Motor A 3 U
Motor A 4 U
Motor A 4 V
Motor A 5 U
Motor A 3 V
Motor A 4 W
Motor A 5 V
Motor A 5 W
Motor A 3 W
Module frame
----

The following table represents the connector pin allocation of the wrist I/O cable with connector X32 on the robot controller and connector CN20 on the robot.

Fig. 1-10: Connector X32 - CN20

Connector X32
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6

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Connector CN20
Pin 13
Pin 14
Pin 15
Pin 16
Pin 3
Pin 4

Signal
$OUT9
$OUT11
$OUT13
$OUT15
$IN9
$IN11

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KR 5 sixx R650, R850

Connector X32
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
Pin 15
Pin 16
Pin 17
Pin 18
Pin 19
Pin 20
Pin 21
Pin 22
Pin 23
Pin 24
Pin 25

Connector CN20
Pin 5
Pin 12
Pin 2
Pin 11
N. C.
N. C.
N. C.
Pin 17
Pin 18
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 1
Pin 19
Pin 20
N. C.
N. C.

Signal
$IN13
0 V internal
0 V internal
Spare
N. C.
N. C.
N. C.
$OUT10
$OUT12
$OUT14
$OUT16
$IN10
$IN12
$IN14
24 V internal
24 V internal
Spare
N. C.
N. C.

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

[SRIO]
INB0=0
OUTB0=0
INB0=1
OUTB0=1

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;$IN[1...8]
;$OUT[1...7]
;$IN[9...14]
;$OUT[9...16]

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2. Technical data

Technical data

2.1

Basic data

Basic data

Type
Number of axes
Volume of working
envelope
Repeatability
(ISO 9283)
Working envelope reference point
Weight

Vibration stress

KR 5 sixx R650 1.0 m3

KR 5 sixx R850 2.3 m3
KR 5 sixx R650 0.02 mm
KR 5 sixx R850 0.03 mm
Intersection of axes 4 and 5
KR 5 sixx R650 approx. 28 kg
KR 5 sixx R850 approx. 29 kg
See Loads acting on the foundation

Principal dynamic
loads
Protection classification of the robot
Sound level
Mounting position
Surface finish, paintwork

IP 40, ready for operation, with connecting

cables plugged in (according to EN 60529)
< 75 dB (A) outside the working envelope
Floor or ceiling
Plastic: white, paintwork: white, base frame:
black

Operation

No permanent vibration stress permissible

Storage and transportation

Ambient temperature

KR 5 sixx R650, KR 5 sixx R850

6

Operation

Brief, one-off: 0.5 g

Brief, one-off: 3 g

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

Relative air humidity 90%

Storage and transportation

No condensation permissible.
263 K to 333 K (-10 C to +60 C)
Relative air humidity 75%
No condensation permissible.

Ambient conditions

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

Connecting cables

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Free from inflammable dust, gases and liquids

Free from aggressive and corrosive gases

and liquids

Free from flying parts

Free from spraying liquids

Free from electromagnetic loads, e.g. from

welding equipment or high-frequency converters

Cable lengths: 4 m, 6 m, 12 m

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KR 5 sixx R650, R850

The connecting cables consist of the motor/data cable and the wrist I/O cable.
The following connector designations and connections are used:
Cable designation
Motor/data cable
Wrist I/O cable
Ground conductor

Connector
designation
X20 - CN22
X32 - CN20
PE

Robot controller - Robot

Harting circular connector
D-Sub circular connector
M5 cable lug at each end

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 robots.

Axis data
Axis

Range of motion, softwarelimited

Speed with rated payload 5

kg

+/-170

375 /s with R650

+45 to -190

250 /s with R850

300 /s with R650

+166 to -119 with R650

250 /s with R850

375 /s with R650

4
5
6

+169 to -119 with R850

+/-190
+/-120
+/-350

250 /s with R850

410 /s
410 /s
660 /s

The direction of motion and the arrangement of the individual axes may be noted from the following diagram.

Fig. 2-1: Robot axes

Working envelope

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

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2. Technical data

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

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KR 5 sixx R650, R850

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

Robot
In-line wrist
Rated payload
Distance of the load center of gravity Lx

KR 5 sixx
IW 5
5 kg
80 mm

Distance of the load center of gravity Ly

0 mm

Distance of the load center of gravity Lz

150 mm

Max. total load

5 kg

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.

Fig. 2-4: Payload on the robot

1
2
3
4
Payload diagram

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FLANGE coordinate system

Load center of gravity
Robot
Distances LX, LY, LZ of the load center of gravity

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

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KR 5 sixx R650, R850

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. Exceeding 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 accordance with operating and programming instructions of the KUKA System Software.
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

Mounting flange
Screw quality
Screw size
Grip length
Depth of engagement
Locating element

DIN/ISO 9409-1-A31,5
10.9
M5
1.5 x nominal diameter
min. 6 mm, max. 8 mm
5 H7

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 (bushing) in the zero position.

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2. Technical data

Fig. 2-6: Mounting flange

Supplementary load

2.4

The robot cannot carry supplementary loads.

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. 2-7: Loads acting on the foundation

Type of load

Force/torque/mass

Fv = vertical force

Fvmax = 1 000 N

Fh = horizontal force

Fhmax = 1 050 N with R650

Fhmax = 850 N with R850

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KR 5 sixx R650, R850

Type of load

Force/torque/mass

Mk = tilting moment

Mkmax = 1 000 Nm with R650

Mkmax = 1 100 Nm with R850

2.5

Mrmax = 1 100 Nm

Total mass

33 kg with R650

Robot mass

34 kg with R850
28 kg with R650

Total load

29 kg with R850
5 kg

Additional data

Valve assembly

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Mr = torque

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.
Designation

Limit values

Valve type
Operating pressure,
infeed
Max. pressure
Switching frequency
Operating temperature

5/2 pulse valve

0.1 to 0.3 MPa
0.59 MPa
10 Hz
268 K to 323 K (-5 C to 50 C)

Threaded union
Medium
Operating voltage
Current

condensation-free
M5 PT1/4
Air, oil-free
24 V 10%
0.5 W, 21 mA

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2. Technical data

Fig. 2-8: Valve diagram

Signal
N. C.
$OUT9

Connector
X32
Pin 8
Pin 1

Connector
CN20
Pin 12
Pin 13

Valve connector
Pin 1
Pin 2

$OUT10

Pin 14

Pin 17

Pin 6

$OUT11

Pin 2

Pin 14

Pin 3

$OUT12

Pin 15

Pin 18

Pin 7

$OUT13

Pin 3

Pin 15

Pin 4

$OUT15

Pin 4

Pin 16

Pin 5

Description
0 V internal
Valve 1 position A
Valve 3 position A
Valve 1 position B
Valve 3 position B
Valve 2 position A
Valve 2 position B

Accessories

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

Fastening threads

The fastening holes serve for fastening the covers, axis range limitations or cable harnesses.

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KR 5 sixx R650, R850

Fig. 2-9: Fastening threads

1
2
3
4
5

24 / 55

2 holes, M3, 7 mm deep

2 holes, M4, 16 mm deep
2 holes, M3, 7 mm deep; distance 104.5 mm
2 holes, M5, 12 mm deep
2 holes, M8, 25 mm deep (transportation)

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3. Safety

Safety

3.1

Designated use
Handling and machining workpieces in dry rooms.

Use

Misuse

Any use or applications deviating from the designated use is deemed to be impermissible misuse; examples of such misuse include:

Transportation of persons and animals

Use as a climbing aid

Operation outside the permissible operating parameters

Use in potentially explosive environments

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

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 declaration of conformity forms the basis for the CE mark for the system. The robot 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 incorporation

3.2.2

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

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 specifications.
Further information is contained in the robot operating instructions.

Robot controller

It is imperative to comply with the minimum clearances of the robot controller

from walls, cabinets and other system components.
Further information is contained in the robot controller operating instructions.

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KR 5 sixx R650, R850

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 ensure a safe state in the case of an Emergency Stop.
Further information is contained in the robot controller operating instructions.

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.

Further information is contained in the corresponding standards and regulations.

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 system (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 Emergency Stop function.

If the safety gate is closed, the robot cannot be started immediately in Automatic mode. The message on the control panel must be acknowledged.

Further information is contained in the corresponding standards and regulations.

Other safety
equipment

3.2.4

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

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 danger to persons or the risk of material damage.

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3. Safety

Fig. 3-1: Example of axis range A1

1
2
3

Workspace
Robot
Braking distance

4
5

3.3

Description

3.3.1

Category of the safety-oriented circuits

Safety zone
Braking distance

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

3.3.2

EMERGENCY STOP systems

Enabling switches

Operator safety

Operating modes

Qualifying inputs

Stop reactions
Stop reactions of the robot system are triggered in response to operator actions or as a reaction to monitoring functions and error messages. The following 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.
Trigger

T1, T2

AUT, AUT EXT

EMERGENCY STOP

Path-oriented braking
(STOP 0)

Path-maintaining braking
(STOP 1)
-

Start key released

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Ramp-down braking
(STOP 2)

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Trigger

T1, T2

Enabling switch
released
Safety gate opened

Path-oriented braking
(STOP 0)
-

"Drives OFF" key

pressed
Operating mode
change
Encoder error
(DSE-RDC connection broken)
Motion enable canceled
STOP key pressed
Controller shut down

AUT, AUT EXT

-

Path-maintaining braking
(STOP 1)
Path-oriented braking
(STOP 0)
Path-oriented braking
(STOP 0)
Short-circuit braking

Ramp-down braking
(STOP 2)
Ramp-down braking
(STOP 2)
Short-circuit braking

Power failure
Stop reaction

Drives

Brakes

Software

Ramp-down
braking
(STOP 2)
Path-maintaining braking
(STOP 1)
Path-oriented
braking
(STOP 0)

Remain on.

Remain open.

Switched off
after 1 second
hardware
delay.
Switched off
immediately.

Applied after
1 s at latest.

Applied immediately.

Switched off
immediately.

Applied immediately.

Normal ramp which is

used for acceleration
and deceleration.
In this time the controller brakes the robot on
the path using a steeper stop ramp.
The controller attempts
to brake the robot on
the path with the remaining energy. If the
voltage is not sufficient, the robot leaves
the programmed path.
-

Short-circuit
braking

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 and

cable markings

on the robot system.

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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 authorization of KUKA Roboter GmbH. Additional components (tools, software, etc.),
not supplied by KUKA Roboter GmbH, may be integrated into the robot system. 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.
Safety features

T1

T2

AUT

AUT EXT

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

Operator safety

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

3.4.2

ESC safety logic

The ESC (Electronic Safety Circuit) safety logic is a dual-channel computeraided safety system. It permanently monitors all connected safety-relevant
components. In the event of a fault or interruption in the safety circuit, the power 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 STOP

External EMERGENCY STOP

Operator safety

Enabling

Drives OFF

Drives ON

Operating modes

Qualifying inputs

Further information is contained in the robot controller operating instructions.

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3.4.3

Operator safety input

The operator safety input is used for interlocking fixed guards. Safety equipment, 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 deceleration. 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.
Further information is contained in the robot controller operating instructions.

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.

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

1

3.4.5

EMERGENCY STOP button

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 maximum deceleration.

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3. Safety

Fig. 3-3: Enabling switches on the KCP

1-3

3.4.6

Enabling switches

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 deactivated 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.
Danger!
If the robot hits an obstruction, a mechanical end stop or an axis range limitation, 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.

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.

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Further information is contained in the operating and programming instructions.

3.5

Personnel

Betreiber

Der Betreiber eines Robotersystems ist fr dessen Benutzung verantwortlich.

Er muss fr einen sicherheitstechnisch einwandfreien Betrieb sorgen und alle
Sicherheitsmanahmen fr 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:

Operator

Example

Installing the robot system

Connecting the robot system

Implementing the required facilities

Issuing the declaration of conformity

Attaching the CE mark

The operator must meet the following preconditions:

The operator must have read and understood the robot system documentation, 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 experience, and their familiarization with the relevant standards, are able to
assess the work to be carried out and detect any potential dangers.

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

Tasks

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Operator

Programmer

Maintenance
technician

Switch robot
controller on/off

Start program

Select program

Select operating
mode

Calibration
(tool, base)

Master the robot

Configuration

Programming

Start-up

Maintenance

Repair

Shut-down

Transportation

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3. Safety

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

3.6

Safety measures

3.6.1

General safety measures

The robot system may only be used in technically perfect condition in accordance 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.
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.

KCP

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.
The following tasks must be carried out in the case of faults to the robot system:

Faults

3.6.2

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.

Transportation

Robot

The prescribed transport position of the robot must be observed. Transportation must be carried out in accordance with the robot operating instructions.
Further information is contained in 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.
Further information is contained in the robot controller operating instructions.

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3.6.3

Start-up
The robot controller must not be put into operation until the internal temperature of the cabinet has adjusted to the ambient temperature. Otherwise, condensation 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 functional.

All electrical connections are correct.

The peripheral devices are correctly connected.

The external environment corresponds to the permissible values indicated

in the operating instructions.

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

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

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, appropriate 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 result 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 danger zone of the robot:

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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.

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3. Safety

3.6.5

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 persons must remain in constant visual contact and have an unrestricted view
of the robot system.

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

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

Hole pattern

The following holes must be used for mounting the robot.

Fig. 4-1: Hole pattern

4.2

Connecting cables and interfaces

Description

The connecting cables comprise all the cables for transferring energy and signals between the robot and the robot controller. A control cable and 2 compressed 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).

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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.

Fig. 4-2: Interface A 1

1
2
3
4
5
In-line wrist interface

Ground conductor connection M5

Motor/data cable CN22
Compressed air connection AIR1, PT1/4
Compressed air connection AIR2, PT1/4
Wrist I/O cable CN20

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

Fig. 4-3: In-line wrist interface

1
2
3
4
5

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Connector CN21, wrist I/O cable

Valve 1, M5
Compressed air connection AIR2, M5
Valve 2, M5
Valve 3, M5

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5. Transportation

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. Remove all transport safeguards, such as nails and screws, in advance. First remove any rust or glue on contact surfaces.

Transport position

The robot must be in the transport position (>>> Fig. 5-1) before it can be
transported. The robot is in the transport position when the axes are in the following positions:
Type
KR 5 sixx

A 1 []
0

A 2 []
-145

A 3 []
+163

A 4 []
+90

A 5 []
+90

A 6 []
0

Fig. 5-1: Transport position

Transport dimensions

The dimensions for the robot (>>> Fig. 5-2) (1) can be noted from the following 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 without equipment.
For transportation, 2 eyebolts (3) must be inserted.

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Fig. 5-2: Transport dimensions

1
2
3
Transportation

Robot
Center of gravity
Eyebolts

*
**

KR 5 sixx R650
KR 5 sixx R850

The robot can be transported by fork lift truck or using lifting tackle. Ceilingmounted robots are brought to the installation site already in the correct installation position.
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.

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.

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

Transportation
using lifting tackle

40 / 55

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 attached 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 damaged.

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5. Transportation

Caution!
The robot may tip during transportation. Risk of injury and damage to property.
If the robot is being transported using lifting tackle, special care must be exercised 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
2
3

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Lifting tackle
Eyebolts
Rotating column

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6. Start-up

Start-up

6.1

Installing a floor-mounted robot

Description

This description is valid for the installation of floor-mounted robots. The installation and start-up of the robot controller is described in the robot controller operating 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 locating 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.

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

16. Mount the tool.
Further information is contained in the operating and programming instructions.

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7. Applied norms and regulations

Applied norms and regulations

Name

Definition

Edition

73/23/EEC

Low Voltage Directive:

1993

89/336/EEC

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
EMC Directive:

1993

97/23/EC

Council Directive of 3 May 1989 on the

approximation of the laws of the Member
States relating to electromagnetic compatibility
Pressure Equipment Directive:

1997

98/37/EC

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
Machinery Directive:

1998

EN 418

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
Safety of machinery:

1993

EN 563

EMERGENCY STOP equipment, functional aspects; principles for design

Safety of machinery:

2000

EN 614-1

Temperatures of touchable surfaces Ergonomics data to establish temperature limit values for hot surfaces
Safety of machinery:

1995

EN 775

Ergonomic design principles Part 1:

Terms and general principles
Industrial robots:

1993

EN 954-1

Safety
Safety of machinery:

1997

EN 55011

EN 60204-1

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

Industrial, scientific and medical (ISM)
radio-frequency equipment Radio disturbance characteristics Limits and
methods of measurement
Safety of machinery:

2003

1998

Electrical equipment of machines - Part

1: General requirements

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Name

Definition

Edition

EN 61000-4-4

Electromagnetic compatibility (EMC):

2002

EN 61000-4-5

Part 4-4: Testing and measurement techniques - Electrical fast transient/burst

immunity test
Electromagnetic compatibility (EMC):

2001

EN 61000-6-2

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

Electromagnetic compatibility (EMC):

2002

EN 61000-6-4

Part 6-2: Generic standards - Immunity

for industrial environments
Electromagnetic compatibility (EMC):

2002

EN 61800-3

Part 6-4: Generic standards; Emission

standard for industrial environments
Adjustable speed electrical power drive
systems:

2001

EN ISO 12100-1

Part 3: EMC product standard including

specific test methods
Safety of machinery:

2004

EN ISO 12100-2

Basic concepts, general principles for

design - Part 1: Basic terminology, methodology
Safety of machinery:

2004

Basic concepts, general principles for

design - Part 2: Technical principles

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8. KUKA Service

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

Information

8.2

The following information is required for processing a support request:

Model and serial number of the robot

Model and serial number of the controller

Model and serial number of the linear unit (if applicable)

Version of the KUKA System Software

Optional software or modifications

Archive of the software

Application used

Any external axes used

Description of the problem, duration and frequency of the fault

KUKA Customer Support

Availability

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

Argentina

Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

Australia

Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au

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Austria

KUKA Roboter GmbH

Vertriebsbro sterreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at

Belgium

KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be

Brazil

KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guan
CEP 02151 900 So Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br

Chile

Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl

China

KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.

Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn

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8. KUKA Service

France

KUKA Automatisme + Robotique SAS

Techvalle
6 Avenue du Parc
91140 Villebon s/Yvette
France
Tel. +33 1 6931-6600
Fax +33 1 6931-6601
commercial@kuka.fr
www.kuka.fr

Germany

KUKA Roboter GmbH

Blcherstr. 144
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de

Hungary

KUKA Robotics Hungaria Kft.

F t 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

India

KUKA Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
info@kuka.in
www.kuka.in

Italy

KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

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KR 5 sixx R650, R850

Korea

KUKA Robot Automation Korea Co. Ltd.

4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com

Malaysia

KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my

Mexico

KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx

Norway

KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjvik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no

Portugal

KUKA Sistemas de Automatizacin S.A.

Rua do Alto da Guerra n 50
Armazm 04
2910 011 Setbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt

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8. KUKA Service

Russia

KUKA-VAZ Engineering
Jushnoje Chaussee, 36 VAZ, PTO
445633 Togliatti
Russia
Tel. +7 8482 391249 or 370564
Fax +7 8482 736730
Y.Klychkov@VAZ.RU

South Africa

Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Spain

KUKA Sistemas de Automatizacin S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltr (Barcelona)
Spain
Tel. +34 93 814-2353
Fax +34 93 814-2950
Comercial@kuka-e.com
www.kuka-e.com

Sweden

KUKA Svetsanlggningar + Robotar AB

A. Odhners gata 15
421 30 Vstra Frlunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se

Switzerland

KUKA Roboter Schweiz AG

Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

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Taiwan

KUKA Robot Automation Taiwan Co. Ltd.

136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
www.kuka.com.tw

Thailand

KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de

UK

KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk

USA

KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com

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Index

Index
Numbers
73/23/EEC 25, 45
89/336/EEC 25, 45
97/23/EC 45
98/37/EC 25, 45
A
Accessories 5, 23
Additional data 22
Ambient conditions 15
Ambient temperature 15
Applied norms and regulations 45
Arm 6
Automatic mode 35
Axis data 16
B
Base frame 6
Basic data 15
Betreiber 32
Brake defect 33
Braking distance 27
Braking, path-maintaining 28
Braking, path-oriented 28
Bypack connector 12
C
Cable designation, connecting cables 11
Category 3 27
CE mark 25
Center of mass 39
Circuits, safety-oriented 27
Configuration, connecting cables 11
Connecting cables 5, 11, 15, 37
Connecting cables, description 11
Connector pin allocation, motor/data cable 12
D
Declaration of incorporation 25
Description 27
Designated use 25
Dimensions, transport 39
Drives OFF 29
Drives ON 29
E
EC declaration of conformity 25
Electrical installations 7
Electrical installations, description 7
EMC Directive 25, 45
EMERGENCY STOP 26, 27
EMERGENCY STOP button 29, 30
EMERGENCY STOP function 35
EN 418 45
EN 55011 45
EN 563 45
EN 60204-1 45

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EN 61000-4-4 46
EN 61000-4-5 46
EN 61000-6-2 46
EN 61000-6-4 46
EN 614-1 45
EN 61800-3 46
EN 775 45
EN 954-1 27, 45
EN ISO 12100-1 46
EN ISO 12100-2 46
Enabling 29
Enabling switches 29, 30, 31
ESC 29
External EMERGENCY STOP 29
External safeguards 26
F
Fastening threads 23
Faults 33
Floor-mounted robot 43
Fork lift truck 40
Function test 34
G
General safety measures 33
Guard interlock 30
H
Handling equipment 40
I
In-line wrist 6
In-line wrist interface 38
Installation site 25
Interface A 38
Interface A 1 7
Interfaces 37
J
Jog mode 29, 31
K
KCP 5, 33
KUKA Customer Support 47
L
Labeling 28
Lifting tackle 40
Link arm 6
Load bearing capacity of ceiling 25
Load bearing capacity of ground 25
Load bearing capacity of wall 25
Loads acting on the foundation 21
Local EMERGENCY STOP 29
Locating pin 43
Low Voltage Directive 25, 45

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M
Machinery Directive 25, 45
Mechanical end stops 31
Mounting flange 20
O
Operating modes 29
Operator 32
Operator safety 29, 30
Operator safety input 30
Options 5
Overload 33
Overview of the robot system 5
Overview of the safety features 29
P
Panic position 30, 31
Path-maintaining 28
Path-oriented 28
Payload diagram 19
Payloads 19
Pressure Equipment Directive 45
Principal components 5
Product description 5
Programming 34

Technical data 15
Transport position 33, 39
Transportation 33, 39
V
Valve assembly 22
Valve group 6
Vibration stress 15
W
Wiring diagrams, data cable 9
Wiring diagrams, motor cable 8
Wiring diagrams, wrist I/O cable 10
Working envelope 16
Workspace 26, 27
Wrist I/O cable 6
Wrist I/O cable, connector pin allocation 13

R
Ramp-down braking 28
Reduced velocity 29
Robot 5, 27
Robot controller 5
Robot system 5
Rotating column 6
S
Safety 25
Safety features 29
Safety fences 26
Safety gates 26
Safety information 29
Safety logic 29
Safety zone 26, 27
Safety-oriented circuits 27
Service, KUKA Roboter 47
Setting 34
Short-circuit braking 28
Software 5
Software limit switches 29, 31
Start-up 34, 43
STOP 0 27
STOP 1 27
STOP 2 27
Stop reactions 27
Supplementary load 21
Support request 47
System integrator 25, 32
System planning 25
T
Teach pendant 5

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