KUKA KR 20 SCARA CS Robot Assembly Instructions

Product Description

System composition

Robot arm body+KR CS Box-2 control cabinet+smartPAD touch teaching pendant+motor cable, encoder data cable+system software+optional accessories.

Main mechanical structure (4-axis SCARA)

A1/A2 horizontal rotary joint; A3 ball spline Z-axis vertical lifting shaft; A4 end rotation axis;

Main components: connecting rod arm, main arm, ball spline, base frame;

Electrical components: protective circuits, cables for each axis motor I/O、 Air interface, Ethernet;

Reserved auxiliary load installation bracket on the arm, capable of mounting external pipeline accessories.

Designated use and prohibition of misuse

Designated use: Tool/fixture handling, workpiece processing and transportation, must be used within the environmental parameters specified in the manual.  

Prohibition: Carrying people and animals, climbing pedals; Outdoor, explosion-proof, radioactive, underground mining; Unauthorized drilling or modification of the main structure by KUKA will result in the loss of warranty.

The main body belongs to partially completed machinery and cannot be directly put into operation independently. It must be integrated into the entire set of equipment.

Safety

Legal responsibility: Declaration of incorporation attached to the entity; The overall risk assessment, EC conformity declaration, CE marking, and terminal operation manual all belong to the system integrator. Unauthorized modification of the entity, all risks are borne by the user/integrator.

Personnel classification: system integrators, operators, debugging, maintenance, and cleaning personnel; The deep disassembly and repair of the main body is only for authorized personnel of KUKA.

Area Definition

Workplace: Robot’s reachable range of motion;

Dangerous area=workspace+parking distance, must be physically protected by fencing/grating; If there is no physical protection, all conditions of EN   ISO   10218 collaborative robots must be fully implemented.

protective device

A1/A2 axis configuration with mechanical hard limit; After hitting the hard limit, the machine must be stopped to contact the KUKA and cannot be directly reused;

Brake release button (A2 arm side), manually move A3/A4 axis in power-off state;

The body nameplate and warning label are strictly prohibited from being removed or altered.

Core Security Points

After power failure, there is a risk of brake failure and falling. Before maintenance, the robotic arm should be placed in a safe position and necessary mechanical support should be provided; Personnel are prohibited from staying below the hazardous area of the robot.

The high temperature of the motor operating casing poses a risk of burns; Repair live parts: If only pressing the emergency stop button is insufficient, the main power switch must be disconnected and the power must be checked to confirm power failure; After the controller is powered off, the internal high-voltage capacitor still maintains high voltage for several minutes.

After the teaching pendant is disconnected, its emergency stop fails; Disconnecting the teaching pendant must be removed from the work site.

After modifying hardware, software, and parameters, all programs must undergo low-speed testing in T1 mode; The program generated by simulation must also undergo T1 testing.

Fault handling: Power off, lock and tag, post fault warning labels; Perform a full set of safety function verification after fault repair.

Technical Data (4 Subdivision Models)

4 models: KR20 R800 Z450‑2CS、KR20 R1000 Z450‑2CS、KR20 R1200 Z450‑2CS、KR20 R1200 Z390‑2CS‑CR（ Clean version with shortened Z-travel.

Parameter KR20 R800 Z450 CS R1000 Z450 CS R1200 Z450 CS R1200 Z390 CS-CR

Axis number 4 4 4 4

Rated load 10   kg 10   kg 10   kg 10   kg

Maximum load 20   kg 20   kg 20   kg 20   kg 20   kg

Maximum arm span 800   mm 1000   mm 1200   mm 1200   mm

Z stroke 450   mm 450   mm 450   mm 390   mm

XY repeat positioning ± 0.025   mm ± 0.025   mm ± 0.035   mm ± 0.035   mm

Z repeat positioning ± 0.01   mm ± 0.01   mm ± 0.01   mm ± 0.01   mm

R repeat positioning ± 0.01 °± 0.01 °± 0.01 °± 0.01 °

Protection level IP20 IP20 IP20 IP54

Body weight~61 kg~61.3 kg~63.2 kg~64 kg

Controller KR CS Box-2 KR CS Box-2 KR CS Box-2 KR CS Box-2

Environmental conditions: Operating at 0~45 ℃; Storage -25~+55 ℃, environmental level 3K22; Low temperature start-up requires preheating and deceleration.

A4 flange: maximum moment of inertia Iz=1   kg · m ², rated at 0.1   kg · m ²; The load mass and moment of inertia must be verified simultaneously and entered into the KUKA. ControlStudio controller software; The manual comes with load curve diagrams for each model, with the load center of gravity based on the A4 flange end face.

Flange load: Provide axial force, radial force, overturning torque, and rotational torque for normal operating conditions and emergency stop impact conditions respectively.

Base load: Given the vertical force, horizontal force, overturning moment, and torsional moment of the ground mounted state, the user base design takes the maximum value.

Shutdown distance and downtime: STOP0 and STOP1 provide A1-A3 axis test data tables; The manual values are for reference only, and the actual shutdown distance must be measured at the project site based on actual operating conditions.

REACH Article 33 Compliance Statement.

Project Planning

Base planning: The robot requires users to design their own steel installation base; Base plate thickness ≥ 20mm, flatness ≤ 0.4mm; provide base installation hole diagram; The maximum allowable tilt angle for installation is 5 °.

Cables and interfaces

Motor cable X30, data cable X31; WEIPU connector; Cable options include 5 μ m/10 μ m;

Fixed laying bending radius: motor cable ≥ 55   mm; data cable ≥ 45   mm; cables are laid separately in metal cable trays to meet EMC requirements;

A1 base interface: X40 I/O, X74 Ethernet interface, 3-channel pneumatic interface AIR1-AIR3;

A2 upper arm interface: X41 I/O, X94 Ethernet interface, brake release button; All gas pipelines are prefabricated inside the machine.

User side pipeline layout: M4/M6 threaded installation bracket reserved at the arm; It is prohibited to directly bind cables to corrugated pipes, and high flexibility shielded cables must be used.

Accelerated wear condition prompt: Long term temperature limit, corrosive environment, continuous full load, monotonic reciprocating motion, external process force, need to shorten maintenance cycle.

Transportation

Robots must enter the designated transport posture and dismantle tools;

Handling method: original packaging box forklift transportation; Alternatively, the base can be screwed into M10 eyebolts to lift the crane body;

The length of the lifting rope is greater than 1500mm; personnel are prohibited from standing under the robot during the entire lifting process; Do not drag cables.

Startup and Debugging

User base leveling, maximum tilt not exceeding 5 °; Pre installed positioning pin; Vertical lowering of the robot body by the crane;

Tighten the M12/M14 fixing bolts of the base diagonally according to the specified torque;

Wiring: equipotential grounding, motor cables, data cables; Perform equipotential continuity testing;

Manual axis movement: A1/A2 releases the brake through Servo Free software; A3/A4 can be manually moved through the brake release button on the body;

Complete checklist before power on: mechanical fastening, no pulling or wear on cables; Change the factory default password; Test run all programs in T1 mode.

Maintenance (a large number of on-site executable maintenance items)

Before maintenance operation: emergency stop+power off, lock and tag; Only use KUKA designated lubrication consumables.

Maintenance cycle maintenance project consumables

Recheck the tightening torque of the base bolts after 100 hours of initial operation

Add lubricating grease THK AFB-LF (approximately 10g) to the ball spline at 100 km or 1500 h

Replace the corrugated pipe at 4000 hours or no later than 1 year; Lubrication of cable assembly; Replace EDS memory battery unit Optitemp RB2 (approximately 20g)

Change the oil in the A1 axis gearbox according to the cycle Optigear ALR320, 0.37   L

Key maintenance details:

Ball spline lubrication: Apply in two positions: upper limit and lower limit; The CR clean version can only be lubricated after disassembling the bellows.

A3/A4 synchronous toothed belt replacement and tension adjustment: Use a frequency meter to measure the vibration frequency of the belt and set the tension. After replacement, perform zero point calibration Mastering.

Battery unit replacement: If the battery fails and loses its zero point, it must be recalibrated after replacement.

Complete process of A1 gear oil discharge and injection;

Cleaning: Stop wiping in case of power outage, do not use high-pressure water gun or steam cleaning.

After replacing the bellows, toothed belt, battery, and gear oil, it is necessary to perform robot zero point calibration Mastering.

Maintenance

Complete process for disassembling, assembling, and replacing the upper cover;

Two schemes for zero point calibration Mastering: ① using specialized calibration fixtures; ② Manual calibration of A1/A2/A3/A4 without tooling;

Only authorized personnel from KUKA are allowed to perform deep disassembly and maintenance of the main body; After the component replacement is completed, conduct a complete safety test and zero calibration.

Discontinuation, Storage, and Scrap Disposal

Deactivation: Adjust to transportation posture, disassemble tools, disconnect power and unplug cables, disassemble the body;

Storage: Dry and dust-free, avoiding condensation; Sealed electrical connectors;

Scrap classification: Motors and RDC/EDS circuit boards are treated as electronic waste, and it is prohibited to disassemble the motor gearbox by oneself; Classification of industrial waste for other mechanical components; The document lists all sealant, gear oil, and lubricant material grades.