KUKA KR IONTEC-2 series six axis industrial robot

Official manual for assembly, debugging, maintenance and repair of KR IONTEC-2 series six axis industrial robots, covering KR25 R3100-2, KR50 R2100-2, KR50 R2500-2, KR70 R2100-2 and multiple derivative variants: D01 high-precision version, F casting version, CR lite clean version; Support KR C5 and KR C5 mid-2 controllers; Support ground, ceiling, and some models support wall mounted installation. 

Product Description

Robot body structure: 6-axis series articulated arm; Core components: coaxial inline wrist, connecting rod arm, rotating column, base frame, and complete cable assembly. The A1-A3 configuration only uses mechanical hard blocks for equipment protection purposes and cannot be used as personnel safety protection. Personal safety relies on the controller’s Safe Robot safety function or optional mechanical axis limit.

Installation Method

Standard models: ground, ceiling; KR50 R2500-2 supports wall mounting.

When not installed on the ground, the installation posture must be configured in the WorkVisual software. Incorrect configuration can cause overload and abnormal movement.

Permitted use: For handling tools, fixtures, and workpiece processing and transportation, it must meet the specified environmental conditions.

Prohibited misuse (misuse directly results in loss of warranty): trampling and climbing, operating beyond specifications, lack of safety protection, carrying people and animals, outdoor activities, explosion-proof areas, radioactive environments, and underground mines.

Body flange: Following ISO 9409-1, different sub models of flanges have different parameters. The document provides detailed flange stress (normal operation+emergency stop conditions).

Additional load interface: The rotating column, connecting rod arm, and boom are all reserved with additional load installation surfaces, with a maximum allowable additional load limit.

Available options: brake manual release device, A1 mechanical limit, pipeline package, lifting plate, fork groove lifting kit, etc.

Technical Data (Massive Model Parameters)

Covering KR25 R3100-2/KR50-R2100-2/KR50-R2500-2/KR70-R2100-2, as well as variant D01 (high precision, repeat positioning ± 0.03mm), F cast version (IP65), CR lite clean version.

Public environmental parameters

Operating temperature: 0~55 ℃; Storage and transportation -25~60 ℃;

Protection level: Standard version IP54; Most wrist models are IP67; F casting machine IP65;

Noise level<80 dB (A); Support ESD IEC61340-5-1;

The cable is compatible with KR C5/KR C5-mid-2, with a cable length of 7-50 meters and a maximum of 50 meters.

Example of Key Parameters for Aircraft Models

KR25 R3100-2: Rated load 25   kg, maximum 33   kg, maximum radius 3100   mm, self weight 510   kg, repeat positioning ± 0.05   mm.

KR50 R2100-2: Rated 50   kg, maximum 66   kg, radius 2100   mm.

KR50 R2500-2: Rated 50   kg, maximum 64   kg, radius 2500   mm, supports wall mounting.

KR70 R2100-2: Rated 70   kg, maximum 87   kg, radius 2100   mm.

Provide complete information for each model: axis motion range, maximum speed of each axis under rated load, load curve diagram, flange load (normal operation, emergency stop impact), base foundation load (ground/ceiling/wall mounted), working envelope diagram, master position, and allowable additional load.

Important reminder: During load verification, it is necessary to verify the quality, center of gravity position, and moment of inertia. KUKA Load software must be used for verification and input into the controller, otherwise the gear motor will be damaged prematurely. This chapter also includes instructions on the location of the body nameplate label, REACH regulation information, and instructions on stopping distance and stopping time.

Planning and Design

Two installation base schemes

R300 × 400 with centering base kit: for concrete foundation, part number 0000-309-857; Including base plate, positioning pin, M20 bolt, chemical anchor bolt; The minimum grade of concrete is C20/25; The uneven foundation allows for leveling mortar, and it is strictly prohibited to pour mortar into bolt holes.

Direct installation of rack frame: directly install customer steel structure/slide table; Relying on cylindrical pins and flat pins for positioning; Tighten 8 M20 bolts diagonally in steps.

Cable planning

Distinguish between KR C5 and KR C5-mid-2 cable definitions: motor cable XD30, data cable XF31, 16 mm ² equipotential grounding conductor. Provide a complete definition of connector pins.

The minimum bending radius requirement requires equipotential, following VDE0100 and EN60204-1.

The rear of the A1 base is the external interface A1, which includes motor, data, optional I/O expansion X76, and air path interfaces AIR1/AIR2.

Long term extreme operating conditions (continuous high temperature, high-frequency start stop, close to performance limit operation) will shorten the service life of components, and maintenance cycles need to be shortened. It is necessary to consult KUKA services.

Transportation

It must be moved to the specified transport posture, and different models are given the angles of each axis.

Two ways of transportation:

Forklift: Use the base fork slot kit, and the fork slot must be fully installed;

Crane lifting: use official lifting tool kit, M12 lifting point; Tools and pipeline packages need to be removed to prevent the center of gravity from shifting.

Avoid impact and vibration during transportation; Prohibit the use of non certified suspension points. Provide the center of gravity coordinates and transportation dimensions for each model.

Startup and Re Debugging

There are two types of startup processes: base kit ground installation and rack mounted (ground/ceiling/wall mounted) installation.

General steps: Install the fork groove lifting device → Clean the installation surface, position the locating pin → Position the robot → Diagonally tighten the M20 bolts in stages → Level the grouting (base kit) → Remove the fork groove lifting device.

Wiring specifications: Grounding M8 nut torque of 15 Nm; motor cable XD30, data cable XF31, connectors must be locked in place with audible clips; The locking buckle can rotate 90 degrees to prevent accidental loosening; Complete the equipotential conduction test.

Set the actual robot installation posture (ground/ceiling/wall mounted) in WorkVisual software.

A4 axis overtravel indicator: After losing zero point mastering, select the correct rotation direction based on the indicator pin position to perform pre calibration notch operation, avoiding wrist cable twisting damage.

T1 mode low-speed whole machine trial run.

Maintenance

Maintenance cycle benchmark

Power on for 100 hours: Check the torque of all fasteners and bolts;

5000 hours: Visually inspect the entire set of A1-A6 cables, and if they are damaged, seek replacement from the warehouse card service;

20000 operating hours or 5 years (whichever comes first): Replace all gearbox oil and lubricate A1 cable sheath.

Lubricating oil: Optigear Synt. ALR 150 is uniformly used for gearboxes, and the filling capacity of each model and shaft is clearly stated in the manual table; Before changing the oil, the robot should be placed in the designated position with the lowest oil outlet; Ventilate and release pressure before draining oil to prevent burns from hot oil; The magnetic plug specifies the tightening torque.

The A1 cable sheath uses Optitemp RB2 grease.

Cleaning: Only solvent-free, water-soluble neutral cleaning agents can be used, and high-pressure steam jet cleaning robots are strictly prohibited.

Maintenance

Chapter description, detailed motor replacement and electrical maintenance refer to corresponding detailed drawings; General safety for motor replacement: When disassembling A2/A3/A5/A6 motors, the arm must be fixed with a sling. If the power is cut off and the brake fails, the arm will fall under its own weight and cause injury; Apply lubricating grease to the new motor spline and replace all O-rings with new ones; Diagonal graded tightening of bolts; After replacing the motor, the axis must be re zeroed for mastering and T1 low-speed testing. Contains the schematic diagram of the micro RDC electrical system.

Retirement, Storage, and Disposal

Dismantling process: The robot moves to the transport posture; Emergency stop, lock and power off; Dismantling tools; Disconnect the gas circuit, cables, and grounding; Loosen the M20 bolt on the base, lift it vertically, and protect the positioning pin.

Storage conditions: The storage environment is dry and dust-free, reducing temperature fluctuations, preventing condensation, and avoiding direct sunlight; Storage -40~60 ℃; Clean and cover the body, remove tool accessories, seal electrical connectors, and place desiccants if necessary.

Scrap and dismantling disposal: Recycling cast aluminum, cast steel, steel, copper cables, and electrical components according to material classification; Gear oil is treated as hazardous waste. The document lists the material list of all components.

Options: Brake Manual Release Device

Purpose: To manually move joints in case of power failure, only used for personnel rescue and escape.

Mandatory warning: After manually moving the joint using the release device, all axes must undergo zero calibration again and brake function testing, otherwise collision injury accidents may occur.