KUKA KR 13 SCARA-2 CS Assembly Manual

Product Description

System composition

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

Main mechanical structure (4-axis SCARA)

A1/A2: Horizontal rotary joint; A3: Z-direction ball spline vertical lifting shaft; A4: End rotation axis.

Main components: Link arm, main arm, ball screw spline, base frame;

Electrical components: protective circuit, A1-A4 motor cables I/O、 Gas interface, Ethernet interface;

Reserved auxiliary load installation bracket on the arm, with a maximum additional load of 2 kg on the arm.

Designated use and prohibition of misuse

Intended use: for handling fixtures, processing workpieces, and transporting workpieces, it must be operated under the environmental parameters specified in the manual.  

Prohibited misuse: manned/animal, climbing pedals; Outdoor, explosion-proof, radioactive, underground mining; Unauthorized drilling or modification of the body structure by KUKA will result in direct loss of warranty; It is not allowed to use it directly in a clean room without protection (except for the CR version).

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.

Security Chapter

Legal responsibility: Randomly attach the Declaration of incorporation; The system integrator is responsible for conducting overall risk assessments, issuing EC compliance statements, affixing CE markings, and writing terminal operation manuals. KUKA is responsible for the mechanical arm components without modifying the ontology; The damage caused by third-party tool software is the responsibility of the integrator.

Personnel classification: system integrator, operator, startup and debugging, maintenance and repair, cleaning personnel; All personnel must read the safety chapter; Deep ontology maintenance is only available to authorized personnel of KUKA.

Area Definition

Workplace: Robot’s movable range;

Dangerous area=workspace+parking distance, must be physically fenced/grating protected;

Safe zone: an area outside the danger zone.

protective device

Mechanical hard limit: A1/A2 axis with mechanical overshoot limit; After hitting the hard limit, it is necessary to stop the machine and contact the warehouse card for inspection. It cannot be directly reused;

Brake release device (optional): manually move each axis in power-off state;

The nameplate warning label is strictly prohibited from being removed or altered.

Key safety points

There is a risk of brake failure and falling after power failure. Before maintenance, the robotic arm should be placed in a safe position and additional mechanical support should be added; Personnel are prohibited from standing below the working area of the robot.

The high temperature of the motor operating casing poses a risk of burns; Electric motors/brakes generate electromagnetic fields; Personnel wearing active implantable devices such as pacemakers should maintain a distance of ≥ 300mm, and both power on and power-off should be effective.

After the smartPAD touch of the teaching pendant is disconnected, its emergency stop fails; The disconnected teaching pendant must be removed from the work site; The function of the teaching pendant enable switch should be tested at least once every 12 months.

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

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

Live parts operation: If only pressing the emergency stop button is insufficient, the main power switch must be disconnected and the power must be checked to confirm that the power is cut off; After the controller is powered off, the internal high-voltage capacitor will still maintain high voltage for several minutes.

The operation of hazardous chemicals requires consulting the Material Safety Data Sheet (MSDS).

Technical Data 

Example of Model Naming Rules: KR 13 R650 Z200-2 CS

13: Maximum load of 13 kg; R650: maximum horizontal reach of 650 mm; Z200: Z-direction travel of 200 mm; CR suffix=cleanroom version. 9 models: KR13 R650-Z200-2CS, R650-Z400-2CS, R650-Z170-2CS-CR;  KR13 R750‑Z200‑2CS、R750‑Z400‑2CS、R750‑Z600‑2CS、R750‑Z170‑2CS‑CR；  KR13 R850‑Z200‑2CS、R850‑Z400‑2CS、R850‑Z170‑2CS‑CR。

Common basic parameters

Number of axes: 4 axes; Rated load of 6 kg, maximum load of 13 kg; upper limit of arm additional load of 2 kg;

XY repeat positioning accuracy ± 0.025mm, Z-direction ± 0.01mm, rotation R-axis ± 0.01 °;

Ordinary CS protection level IP20; CR clean version IP54; Noise level<80 dB (A); Only for ground installation, with a footprint of 210mm for base installation;

Environment: Operating at 0~45 ℃; Storage -25~+60 ℃; Environmental level 3K22;

Controller: KR CS Box-2;

A4 flange maximum moment of inertia Iz=0.3   kg · m ², rated 0.02   kg · m ²; The load mass and moment of inertia must be verified simultaneously and recorded in the controller KUKA. ControlStudio;

Attached are load curve diagrams for each model, with the load center of gravity based on the A4 flange end face;

Provide flange operating load and emergency stop impact load separately; Base foundation load (vertical force, horizontal force, overturning moment, A1 torsional moment);

Provide 2D drawings of the motion envelope for each model (side view, top view);

Shutdown distance/shutdown time: STOP0, STOP1, provide A1-A4 axis reference curve; The manual values are for reference only, and the actual shutdown distance must be measured on the project site under actual working conditions.

REACH Article 33 Compliance Statement.

Project Planning

Installation base: Users must design and process the base themselves, and the manual must be checked to provide the maximum base force; Requirements for flatness of the base installation surface.

Cable planning

Motor cable X30, encoder data cable X31; WEIPU WF series connectors; Optional 3-meter/5-meter/10 meter cables;

Optional equipotential grounding conductor;

Clearly define the minimum bending radius and wiring requirements for cables to avoid pulling and wear;

Installation position of external pipelines and cables on the user side: An auxiliary load bracket is reserved on the arm to support the user in arranging air pipes and cables; Magnetic fasteners are prohibited.

Transportation

Robots must enter the designated transport zero position before being packaged and transported;

Can only be transported in original factory packaging boxes; Avoid impact and vibration;

Key points for lifting and handling, dismantling tools and fixing cables before handling; Do not drag cables.

Startup and Re Debugging

Ground installation process: fixing the base → lifting the body → tightening the bolts;

Cable docking: motor cables, data cables, equipotential grounding, check the joint locking buckle;

Complete specifications of cables and connector dimensions;

Manual movement of each axis method: Instructions for using the brake release device, manually move A1-A4 when powered off;

Complete checklist before power on: mechanical fastening, cables, grounding continuity; Change the factory default password of the system; Test run all programs in T1 mode.

Maintenance (Key, SCARA has a large number of on-site executable maintenance items in this manual)

​Emergency stop, power off, lock and tag must be carried out before maintenance operation.

Maintenance Project Description

There are two different lubrication processes for the CS version and CR clean version of the ball spline lubrication standard; Add lubricating grease to the upper and lower limit positions;

Lubrication and maintenance of motion cables through cable assembly lubrication

Complete disassembly, replacement, and installation steps for replacing the bellows dust cover; Key components of CR clean version

A3/A4 synchronous toothed belt replacement+tension adjustment requires fixing A3 shaft; Replace the toothed belt; Step by step measurement and adjustment of belt tension for A4-1, A4-2, and A3, with tension parameters being the key to accuracy;

Backup battery unit replacement, EDS memory battery replacement, and re zero calibration of Mastering is required after replacement

A1 axis gearbox oil change, oil discharge, and gear oil filling operation process;

Robot cleaning, power outage, emergency stop, wipe and clean, high-pressure flushing is prohibited; CR Clean Edition uses clean compatible wiping media

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

Maintenance

CR Clean Version: Disassembly and replacement process of shaft sleeve cover;

Zero point calibration Mastering: Multiple calibration schemes: Use calibration tools to calibrate A1/A2/A3/A4; Manual calibration process without calibration tools;

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

Discontinuation, Storage, and Scrap Disposal

Deactivation: Adjust to transportation posture, disassemble tools, power off, remove cables, disassemble the body;

Storage: Dry and dust-free, avoid condensation, seal electrical connectors;

Scrap: The motor and circuit board are treated as electronic waste, and it is prohibited to disassemble the motor gearbox by oneself; Classification of industrial waste for other mechanical components; List the list of lubricating grease, gear oil, and sealant materials used.