KUKA 12 SCARA Series 4-axis SCARA Horizontal Joint Robot

KUKA KR 12 SCARA series 4-axis SCARA horizontal joint robot English version assembly manual, compatible with KR C5 micro controller, the robot only supports ground installation; Includes product introduction, safety specifications, full model technical parameters, project planning, transportation, startup debugging, maintenance, shutdown scrapping, options, appendices, technical support, aimed at system integrators, debugging, and maintenance engineers.

Product Description

​List of Robot Family Models

KR 12 SCARA has a total of 6 models:

KR 12 R650 Z400

KR 12 R650 Z340 CR (Clean Edition)

KR 12 R750 Z400

KR 12 R750 Z340 CR (Clean Edition)

KR 12 R750 Z600

KR 12 R850 Z400

KR 12 R850 Z340 CR (Clean Edition)

The complete system consists of a robotic arm body, KR C5 micro control cabinet, smartPAD-2 teaching pendant, motor/data cables, software, and optional accessories.

Structure of Robot Arm Body

4-axis SCARA configuration: A1 rotation, A2 rotation, A3 vertical lifting (ball spline), A4 end rotation. Main components: connecting rod arm, arm, ball spline (Z-axis), base frame, complete set of built-in electrical components.

Arm: Built in A3/A4 motor, driven by A2 motor; Reserved additional load installation interface for the arm; Set mechanical hard limit.

Link arm: connects the base and arm, with mechanical overtravel protection.

Base frame: The entire machine is installed on a base, where motor cables, data cables, and air interface are arranged.

Electrical system: protection circuit, cables for each axis motor, I/O cables, air pipes, Ethernet, controller connection plugs.

2.3 Designated use and prohibition of misuse

Designated use: transporting fixtures and jigs, processing/transferring parts; Must meet the environmental conditions specified in the manual and fully comply with maintenance requirements.

Prohibited misuse: carrying people and animals, climbing frames; Hyperparameter operation; Lack of safety equipment operation; Outdoor, explosion-proof, radioactive, and underground mining environments; Unauthorized drilling and modification of the main structure will result in the loss of all warranty.

Robots belong to the semi-finished products (unfinished machinery) defined by the EU Machinery Directive and cannot be produced separately. They must be integrated into a complete set of CE compliant equipment.

Safety

Legal responsibility framework: Robots belong to semi-finished products; The system integrator is responsible for overall risk assessment, issuing EC compliance statements, and affixing CE markings; KUKA provides an Assembly Declaration. Modifying robots without the manufacturer’s permission may result in loss of warranty claims; The responsibility for damage caused by third-party accessories belongs to the integrator/user.

Personnel classification: system integrators, operators, debugging and maintenance personnel, cleaning personnel; All personnel must read the safety chapter and possess the corresponding qualifications.

Area Definition

Workplace: Robot’s reachable range of motion;

Dangerous area=workspace+stopping distance (including external axis), must be physically fenced for protection;

Safe zone: outside the danger zone.

The body comes with built-in protection: mechanical hard limit; Brake release device (optional for non actuated mobile robotic arm); Main body warning nameplate (no tearing or alteration allowed).

After the mechanical arm collides with the mechanical hard limit, it cannot continue to operate and must be evaluated by KUKA.

Safety measures for various working conditions

General safety: Personnel are prohibited from standing under their arms; After a power outage, there is still a risk of the robotic arm falling, and mechanical support must be provided; High temperature anti scalding of motor operating casing; Personnel wearing pacemakers should be at least 300mm away from the motor/brake; dedicated personnel should be responsible for controlling the teaching pendant; Hardware/program modifications must prioritize T1 mode testing; Fault power outage, locking and tagging.

Transportation: Maintain transportation posture and avoid impact and vibration.

Start/Re debug: Change default password before powering on; Prohibition of mixing robotic arms with non matching controllers; Check the grounding and connectors; Complete safety circuit testing; Avoid condensation.

Manual mode T1/T2: T1 is used for teaching demonstration; T2 is only used for high-speed testing and programming is prohibited; Requirements for personnel working within the protective zone.

Automatic mode: All safety protections are intact, and the dangerous area can only be operated without anyone.

Maintenance and repair: power off and lock; After the main switch is disconnected and the power is verified, the control cabinet can maintain a maximum high voltage of 780V for several minutes after the power is cut off; ESD anti-static; Chemical protection.

Shutdown, storage, and disposal: comply with local regulations.

List of EU directives and standards cited.

Technical Data

All models have a rated load of 6 kg and a maximum load of 12 kg; XY repeat positioning accuracy is ± 0.025 mm, Z-direction ± 0.005 mm, and rotation R-direction ± 0.005 °; The base installation footprint is 210mm × 210mm, and the controller is uniformly KR C5 micro. CR clean version: IP54 protection, RAL9003 white, ISO14644-1 Class5 (100% program magnification); Normal version IP20, Industrial Orange RAL2009. Environmental conditions: Operating at 0~42 ℃; Storage -25~+55 ℃; Low temperature start-up requires pre deceleration acceleration for preheating. Cable optional length 5/10/15/25   m; A3 axis process force 100   N.

Summary of Key Differences among Various Models

Model: Maximum arm span A3, travel, self weight, supplementary load capacity

KR12 R650 Z400 650   mm -400   mm 49   kg Maximum arm weight 2   kg

KR12 R650 Z340 CR 650   mm-340   mm 51   kg Arm maximum 2   kg

KR12 R750 Z400 750   mm -400   mm 50   kg Maximum arm weight 2   kg

KR12 R750 Z340 CR 750   mm-340   mm 52   kg Maximum arm weight 2   kg

KR12 R750 Z600 750   mm -600   mm 50.5   kg No additional load allowed

KR12 R850 Z400 850   mm-400   mm 51   kg Maximum arm weight 2   kg

KR12 R850 Z340 CR 850   mm-340   mm 53   kg Maximum arm weight 2   kg

Axis parameters: A1 ± 145 °; A2 ordinary model ± 135 °, 750/850 model ± 145 °; A3 is the straight-line travel; A4 ±355°； The maximum speed document table under rated load of each axis is listed in detail.

Zero calibration requirement: A3 axis must be calibrated after A4 is calibrated; After completing the calibration, move A3 to the vicinity of the software limit in T1 mode to operate normally.

Mandatory requirement for load verification: Quality and moment of inertia must be verified simultaneously, using KUKA. Load tool, and load parameters must be entered into the controller; Attached are load curve diagrams for each model; Provide flange dimensions, axial force, radial force, overturning moment, and torque for operating/emergency stop conditions.

Base foundation load: Each model provides vertical force Fv, horizontal force Fh, overturning moment Mk, A1 torsional moment Mr; ⚠️ The design of the base structure must use the maximum load value.

Nameplate identification: complete machine nameplate, multilingual safety warning label, do not peel off or apply.

REACH SVHC information.

Stopping distance and stopping time (safety critical):

Definition: Stop distance=Reaction distance+Braking distance, belonging to a part of the danger zone;

STOP0 (category 0) directly cuts off the drive and locks the brake; STOP1 (Category 1) path controlled deceleration shutdown;

Each model provides data tables and curve graphs for different extension lengths of A1-A4 axes under STOP0/STOP1 conditions, stop angles and stop times under different POV program magnifications; The values are for testing reference and require on-site measurement of the project.

Project Planning

Planning reminder: Long term operating temperature/power limits, frequent short cycle movements, static loading, and exposure to external process forces can accelerate component wear and require shorter maintenance cycles. If necessary, consult with KUKA.

Base design: Ground mounted base, concrete/steel structure base, installation positioning pin requirements.

Definition of cables and interfaces: Definition of connectors for motor cables, data cables, grounding, etc; Base end interface X30/X31; I/O、 Gas interface; Cable laying requirements, cables cannot withstand tension, EMC electromagnetic compatibility requirements.

User side cable layout: Arm additional load installation holes, customers can arrange the space and installation specifications of pipelines themselves.

Transportation

Mechanical arm transportation requirements: It must be placed in the designated transportation posture to prevent impact and vibration; Prohibition of rough lifting; Protect flanges and connectors.

Startup and Re Debugging

Complete ground installation steps: base base in place → positioning pin assembly → lifting robot arm positioning → diagonal locking of anchor bolts; Motor cables, data cables, equipotential grounding wiring; Connector locking.

Cable details: connector pins and dimensions for motor cables, data cables, and grounding conductors.

Mobile robotic arm without driving conditions: brake release button; Operation of brake release device options; ⚠️ The axis in an unpowered state may fall and injure people, limited to emergency rescue scenarios.

Maintenance

The maintenance cycle is based on standard operating conditions, and the cycle needs to be shortened for harsh operating conditions.

Maintenance Summary Table

Ball spline (regular version/CR clean version) lubrication; Inject grease at two positions, A3 upper limit and lower limit;

Lubrication of cable components;

A1 axis gearbox oil change;

Robot body cleaning: high-pressure water gun steam cleaning is prohibited; Use compliant cleaning agents.

Describe in detail the step-by-step lubrication process for the standard version and CR cleanroom version ball splines; Complete the operation of draining and adding gear oil to A1 gearbox.

Shutdown, Storage, and Disposal

Shutdown and disassembly: move to the transport position; power failure; Dismantle all cables; Lift the lifting device off the main body; Dust protection for connectors.

Long term storage: maintain transportation posture; Dry and dust-free environment without condensation; Interface sealing protection.

Scrap disposal: motors and circuit boards are used as electrical waste; Aluminum casting metal recycling; Lubricating oil and seals should be treated as hazardous chemicals and comply with local environmental regulations.