Kuka KL 1500-3 User manual
Issued: 16.06.2010
Version: MA KL 1500-3 T S 141215 V1 en
KUKA Roboter GmbH
Linear Units
KL 1500-3; KL 1500-3 T; KL 1500-3 S
Assembly and Operating Instructions
Serial Number 141215
© Copyright 2010
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
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, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
KL 1500-3; KL 1500-3 T; KL 1500-3 S
2 / 151 Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en
Publication: Pub MA KL 1500-3 T S 141215 en
Book structure: MA KL 1500-3 T S 141215 V1.1
Label: MA KL 1500-3 T S 141215 V1
3 / 151Issued: 16.06.2010 Version: MA KL 1500-3 T S 141215 V1 en
Contents
1 Introduction .................................................................................................. 7
1.1 Documentation for the linear unit ............................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9
3 Product description ..................................................................................... 11
3.1 Description of the linear unit ...................................................................................... 11
3.1.1 Description of the beam ........................................................................................ 12
3.1.2 Description of the carriage .................................................................................... 13
3.1.3 Description of the drive assembly ......................................................................... 13
3.1.4 Description of the energy supply system .............................................................. 14
3.1.5 Design of the linear unit ........................................................................................ 16
3.2 Options ...................................................................................................................... 16
3.2.1 Working range monitoring .................................................................................... 16
4 Technical data .............................................................................................. 17
4.1 Basic data ..................................................................................................................17
4.2 Principal dimensions .................................................................................................. 18
4.3 Plates and labels ........................................................................................................ 22
4.4 Order-specific technical data ..................................................................................... 24
4.4.1 Principal dimensions ............................................................................................. 24
5 Safety ............................................................................................................ 27
5.1 General ...................................................................................................................... 27
5.1.1 Liability .................................................................................................................. 27
5.1.2 Intended use of the industrial robot ...................................................................... 28
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 28
5.1.4 Terms used ........................................................................................................... 29
5.2 Personnel ...................................................................................................................29
5.3 Workspace, safety zone and danger zone ................................................................. 31
5.4 Overview of protective equipment .............................................................................. 32
5.4.1 Mechanical end stops ........................................................................................... 32
5.4.2 Mechanical axis range limitation (optional) ........................................................... 32
5.4.3 Axis range monitoring (optional) ........................................................................... 32
5.4.4 Release device (optional) ..................................................................................... 33
5.4.5 Labeling on the industrial robot ............................................................................. 33
5.5 Safety measures ........................................................................................................ 33
5.5.1 General safety measures ...................................................................................... 33
5.5.2 Transportation ....................................................................................................... 35
5.5.3 Start-up and recommissioning .............................................................................. 35
5.5.4 Manual mode ........................................................................................................ 36
5.5.5 Automatic mode .................................................................................................... 37
5.5.6 Maintenance and repair ........................................................................................ 37
5.5.7 Decommissioning, storage and disposal .............................................................. 38
5.6 Applied norms and regulations .................................................................................. 39
Contents
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KL 1500-3; KL 1500-3 T; KL 1500-3 S
6 Planning ........................................................................................................ 41
6.1 Mounting base ........................................................................................................... 41
6.2 Foundation data ......................................................................................................... 42
6.2.1 Loads acting on the foundation ............................................................................ 42
6.2.2 Mounting base variants ........................................................................................ 44
6.3 Connecting cables and interfaces ............................................................................. 50
7 Transportation ............................................................................................. 53
7.1 Transportation of assemblies and components ......................................................... 53
7.2 Transportation of beams ............................................................................................ 53
7.2.1 Transportation by fork lift truck ............................................................................. 53
7.2.2 Transportation by crane ........................................................................................ 54
8 Start-up and recommissioning ................................................................... 55
8.1 Installing the mounting base ...................................................................................... 55
8.2 Installing a linear unit with a one-piece beam ............................................................ 56
8.3 Removing linear unit with one-piece beam ................................................................ 57
8.4 Installing a linear unit with a beam made up of several parts .................................... 58
8.5 Removing a linear unit with a beam made up of several parts .................................. 61
8.6 Installing the energy supply system ........................................................................... 62
8.7 Removing the energy supply system ......................................................................... 64
9 Maintenance ................................................................................................. 65
9.1 Maintenance table ..................................................................................................... 65
9.2 Cleaning the linear unit .............................................................................................. 66
10 Adjustment ................................................................................................... 69
10.1 Adjusting the backlash ............................................................................................... 69
10.1.1 Measuring the backlash ........................................................................................ 70
10.1.2 Adjusting the backlash ......................................................................................... 71
10.2 Adjusting the rollers ................................................................................................... 71
11 Repair ............................................................................................................ 73
11.1 Exchanging the drive assembly ................................................................................. 73
11.1.1 Removing the drive assembly .............................................................................. 73
11.1.2 Installing the drive assembly ................................................................................ 74
11.2 Exchanging the servomotor ....................................................................................... 75
11.2.1 Removing the servomotor .................................................................................... 76
11.2.2 Installing the servomotor ...................................................................................... 76
11.3 Exchanging the upper/lower rollers using the auxiliary device .................................. 78
11.3.1 Installing the auxiliary device ................................................................................ 80
11.3.2 Removing the auxiliary device .............................................................................. 81
11.3.3 Converting the auxiliary device ............................................................................. 82
11.3.4 Removing the upper/lower rollers ......................................................................... 83
11.3.5 Installing the upper/lower rollers ........................................................................... 84
11.4 Exchanging the upper/lower rollers without using the auxiliary device ...................... 85
11.4.1 Removing the upper/lower rollers ......................................................................... 86
11.4.2 Installing the upper/lower rollers ........................................................................... 87
11.5 Exchanging the side rollers ....................................................................................... 87
11.5.1 Removing the side rollers ..................................................................................... 88
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Contents
11.5.2 Installing the side rollers ....................................................................................... 88
11.6 Exchanging the carriage ............................................................................................ 89
11.6.1 Lateral removal of carriage ................................................................................... 90
11.6.2 Lateral installation of carriage ............................................................................... 90
11.6.3 Removing the carriage from above ....................................................................... 91
11.6.4 Installing the carriage from above ......................................................................... 93
12 Electrical installations ................................................................................. 95
12.1 Electrical installations of the linear unit, KR 2000 Series ........................................... 95
12.1.1 Description ............................................................................................................ 95
12.1.2 Cabling diagrams .................................................................................................. 97
12.2 Electrical installations, options ................................................................................... 101
12.2.1 Connecting cable, Multibus cable X71 (optional) .................................................. 101
13 Decommissioning, storage and disposal .................................................. 103
13.1 Decommissioning ....................................................................................................... 103
13.2 Storage ...................................................................................................................... 104
13.3 Disposal ..................................................................................................................... 105
14 Options ......................................................................................................... 107
14.1 Working range monitoring, welded ............................................................................ 107
14.1.1 Technical data ...................................................................................................... 108
14.1.2 Installing the working range monitoring ................................................................ 108
14.1.3 Adjusting the working range monitoring ................................................................ 110
14.1.4 Maintenance instructions ...................................................................................... 113
14.1.5 Electrical installations ........................................................................................... 114
14.2 Connecting cables for working range monitoring ....................................................... 118
14.2.1 Description ............................................................................................................ 118
14.2.2 Cabling diagrams .................................................................................................. 119
15 Appendix ...................................................................................................... 123
15.1 Safety data sheets ..................................................................................................... 123
15.1.1 Safety data sheet for Aralub LFZ 1 lubricating grease ......................................... 123
15.1.1.1 Designation of substance/formulation and manufacturer ..................................... 123
15.1.1.2 Composition / Information about the components ................................................ 123
15.1.1.3 Possible hazards .................................................................................................. 123
15.1.1.4 First aid measures ................................................................................................ 124
15.1.1.5 Fire-fighting measures .......................................................................................... 124
15.1.1.6 Measures after unintended release ...................................................................... 125
15.1.1.7 Handling and storage ............................................................................................ 125
15.1.1.8 Exposure limits and personal protective equipment ............................................. 125
15.1.1.9 Physical and chemical properties ......................................................................... 125
15.1.1.10Stability and reactivity ........................................................................................... 126
15.1.1.11Toxicological information ...................................................................................... 126
15.1.1.12Ecological information ........................................................................................... 126
15.1.1.13Disposal information ............................................................................................. 126
15.1.1.14Transport information ............................................................................................ 127
15.1.1.15Regulations ........................................................................................................... 127
15.1.1.16Other information .................................................................................................. 128
15.1.2 Safety data sheet for Microlube GL 261 lubricating grease .................................. 128
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KL 1500-3; KL 1500-3 T; KL 1500-3 S
15.1.2.1 Designation of substance/formulation and manufacturer ..................................... 128
15.1.2.2 Composition / Information about the components ................................................ 128
15.1.2.3 Possible hazards .................................................................................................. 128
15.1.2.4 First aid measures ................................................................................................ 129
15.1.2.5 Fire-fighting measures .......................................................................................... 129
15.1.2.6 Measures after unintended release ...................................................................... 130
15.1.2.7 Handling and storage ........................................................................................... 130
15.1.2.8 Exposure limits and personal protective equipment ............................................. 130
15.1.2.9 Physical and chemical properties ......................................................................... 131
15.1.2.10Stability and reactivity ........................................................................................... 131
15.1.2.11Toxicological information ...................................................................................... 131
15.1.2.12Ecological information .......................................................................................... 131
15.1.2.13Disposal information ............................................................................................. 132
15.1.2.14Transport information ........................................................................................... 132
15.1.2.15Regulations .......................................................................................................... 132
15.1.2.16Other information .................................................................................................. 132
15.1.3 Safety data sheet for Ferrocote 5856 HF ............................................................. 132
15.1.3.1 Designation of substance/formulation and manufacturer ..................................... 132
15.1.3.2 Composition / Information about the components ................................................ 133
15.1.3.3 Possible hazards .................................................................................................. 133
15.1.3.4 First aid measures ................................................................................................ 133
15.1.3.5 Fire-fighting measures .......................................................................................... 134
15.1.3.6 Measures after unintended release ...................................................................... 134
15.1.3.7 Handling and storage ........................................................................................... 135
15.1.3.8 Exposure limits and personal protective equipment ............................................. 135
15.1.3.9 Physical and chemical properties ......................................................................... 135
15.1.3.10Stability and reactivity ........................................................................................... 136
15.1.3.11Toxicological information ...................................................................................... 136
15.1.3.12Ecological information .......................................................................................... 136
15.1.3.13Disposal information ............................................................................................. 136
15.1.3.14Transport information ........................................................................................... 137
15.1.3.15Regulations .......................................................................................................... 137
15.1.3.16Other information .................................................................................................. 138
16 KUKA Service ............................................................................................... 139
16.1 Requesting support ................................................................................................... 139
16.2 KUKA Customer Support ........................................................................................... 139
Index ............................................................................................................. 147
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1. Introduction
1 Introduction
1.1 Documentation for the linear unit
The linear unit documentation consists of the following parts:
Operating instructions for the linear unit
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.2 Representation of warnings and notes
Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.
Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.
Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.
Tips to make your work easier or references to further information.
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2. Purpose
2 Purpose
2.1 Target group
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of mechanical engineering
Advanced knowledge of electrical and electronic systems
Knowledge of the robot controller system
2.2 Intended use
Use The linear unit is used for linear traversing of a robot or of other equipment.
Use is only permitted under the specified environmental conditions.
Misuse Any use or application deviating from the designated use is deemed to be im-
permissible misuse. This includes e.g.:
Transportation of persons and animals
Use as a climbing aid
Operation outside the permissible operating parameters
Use in potentially explosive environments
For optimal use of our products, we recommend that our customers take part
in a course of training at KUKA College. Information about the training pro-
gram can be found at www.kuka.com or can be obtained directly from our
subsidiaries.
Caution!
Changing the structure of the linear unit, e.g. by drilling holes, etc., can result
in damage to the components. This is considered improper use and leads to
loss of guarantee and liability entitlements.
The linear unit is an integral part of an overall system and may only be oper-
ated in a CE-compliant system.
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3. Product description
3 Product description
3.1 Description of the linear unit
The linear unit is a single-axis unit for horizontal installation. It is used for linear
traversing of the robot or of other equipment. The linear unit is controlled by
the robot controller as an external axis. The rated travel of the carriage is de-
fined specifically for each individual unit. The interval is 500 mm. The linear
unit is available in the variants: standard, T and S.
The linear unit consists of the following components (>>> Fig. 3-1):
Beam
Carriage
Drive assembly
Energy supply system
Variants Use
KL 1500-3 (standard) KR 30 to KR 125, KR 150, KR 200, KR 360,
KR 500; without pedestal
KR 150 to KR 270 (Series 2000); without pedes-
tal
KL 1500-3 T KR 30 to KR 125, KR 150, KR 200, KR 360,
KR 500; without pedestal
KR 30 to KR 125, KR 150, KR 200; with pedes-
tal
KR 150 to KR 270 (Series 2000); with pedestal
KL 1500-3 S KR 30 to KR 125, KR 150, KR 200, KR 360,
KR 500; without pedestal
KR 30 to KR 125, KR 150, KR 200; with pedes-
tal
KR 150 to KR 270 (Series 2000); with pedestal
Fig. 3-1: Structure of the linear unit
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KL 1500-3; KL 1500-3 T; KL 1500-3 S
A linear unit can be equipped with up to four independently controlled carriag-
es. Variants with mirrored design and a tender carriage are also possible. The
carriage is designed to be suitable for every design of linear unit. The tender
carriage does not have a drive of its own. It is moved by being coupled to the
carriage.
The carriage is driven by the drive unit (drive assembly), an AC servomotor
with gearing and a pinion, which engages with a rack. The movement range of
the carriage is limited by programmable software limit switches. It is addition-
ally safeguarded by means of mechanical stops (crash elements).
The carriage is equipped with a horizontal mounting face for mounting the ro-
bot.
The linear unit may optionally be fitted with working range monitoring.
3.1.1 Description of the beam
The beam (>>> Fig. 3-2) serves to fasten the linear unit to the floor. Beyond a
beam length of 10 m, several beams are lined up and screwed together using
a connecting assembly. This ensures that the arrangement of the beams re-
mains the same.
The beam is fastened to the floor through a mounting base. If a number of
beams are fastened together, a special mounting base is used at the joints.
The tracks and racks are screwed onto the beam.
1 Carriage 3 Energy supply system
2 Drive assembly 4 Beam
Fig. 3-2: Beam
1 Cover 4 Buffer
2 Track 5 Connecting assembly
3 Beam 6 Mounting base
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3. Product description
3.1.2 Description of the carriage
The carriage (>>> Fig. 3-3) serves as a mount for the robot. It features a
mounting face which is equipped with two centering pins. The hole pattern on
the mounting face depends on the robot type. The drive unit, and the driver for
the energy supply system, are also fastened to the carriage. The carriage is
guided by means of four roller guides on the tracks of the beam.
The range of motion of the carriage is restricted by programmable software
limit switches. If the permitted movement range is exceeded, the buffers on the
beam bring the carriage to a stop.
The carriage can be mastered with a KTL mastering set. A mount with a gauge
cartridge is provided for this purpose.
3.1.3 Description of the drive assembly
The drive assembly (>>> Fig. 3-4) of the carriage consists of a servomotor, a
gear unit, an intermediate plate and fasteners. The pinion of the drive engages
with the rack on the beam, thereby moving the carriage. The drive assembly
is designed to be suitable for use with both the standard design and the mir-
rored design of linear unit. The drive assembly is fastened to the carriage via
the intermediate plate.
Fig. 3-3: Carriage
1 Driver for energy supply sys-
tem
4 Carriage
2 Roller guide 5 Mounting surface
3 Drive assembly 6 Mount for gauge cartridge
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KL 1500-3; KL 1500-3 T; KL 1500-3 S
Servomotor The servomotor essentially comprises the motor with an integrated solenoid
brake and a position sensing system. The solenoid brake prevents motion of
the carriage at standstill.
The solenoid brake is closed when deenergized, i.e. the armature is pulled
against the solenoid brake by a permanent magnetic field. When current flows
through the solenoid brake, the permanent magnetic field decays and the ar-
mature is released.
The servomotor is fastened on the side of the gear unit. The motor and control
cables are connected by means of the connectors.
Gear unit The motor speed is reduced by the gear unit and transferred by the pinion to
the rack. The gear unit is fastened to the carriage via an intermediate plate.
The backlash is adjusted by means of the eccentric on the intermediate plate.
The gear unit is lifetime-lubricated. The rack and pinion are greased.
3.1.4 Description of the energy supply system
The energy supply system consists of the energy supply chain, the connector
plate and a driver. The energy supply chain contains the supply lines for the
robot and the energy and fluid supply. These supply lines are required for op-
erating the linear unit and the robot and for any connected tools (e.g. spot weld
gun). The energy supply system is supported in guides. It is fastened to the
floor via the connector plate and to the carriage via the driver. The attachment
on the carriage is dependent on the length of the energy supply chain. The
length of the energy supply chain depends on the travel of the carriage.
Figure (>>> Fig. 3-5) below shows the two variants for attaching the energy
supply system. These depend on the travel (H) of the carriage and on the
chain width (BK).
Fig. 3-4: Drive assembly
1 Gear unit 5 Servomotor
2 Intermediate plate 6 Connector XP7, control cable
3 Eccentric 7 Connector XM7, motor cable
4Pinion
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3. Product description
Trough system The energy supply chain lies in a trough system (>>> Fig. 3-6) manufactured
by IGUS.
The trough system consists essentially of two troughs and C-profiles. The C-
profiles are positioned at right angles to the troughs. The length of the troughs
and the number of C-profiles depend on the travel of the linear unit and thus
on the length of the energy supply chain. The trough system is fastened via
the C-profiles to the floor using chemical anchors.
Fig. 3-5: Attaching the energy supply system
1 Energy supply system for rated travels of up to 7,500 mm (6,500
mm)
2 Energy supply system for rated travels greater than 8,000 mm
(7,000 mm)
See the assembly instructions from IGUS.
Fig. 3-6: Trough system (example)
1 Carriage 6 C-profiles
2 Driver 7 Trough
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KL 1500-3; KL 1500-3 T; KL 1500-3 S
3.1.5 Design of the linear unit
Description The possible variants of the linear unit are shown in the illustration (>>> Fig.
3-7).
Direction of travel Direction of travel of the linear unit is always determined by the first carriage.
In the illustration (>>> Fig. 3-7), the first carriage is indicated with “1”. By de-
fault, the carriage moves in the minus direction when moving away from the
starting point. The travel of the carriage in the plus direction is motion towards
the starting point. If more than one carriage is used on a single linear unit, the
direction of travel of the other carriages corresponds to that of the first car-
riage.
3.2 Options
3.2.1 Working range monitoring
The linear unit may optionally be fitted with working range monitoring.
3 Energy supply chain 8 Fixed point module
4 Screw anchor 9 Connecting cables
5 Trough system 10 Connector plate
Fig. 3-7: Design and direction of travel of the linear unit
1 Linear unit, standard design, rotated
2 Linear unit, mirrored design
3 Linear unit, standard design
4 Linear unit, mirrored design, rotated
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4. Technical data
4 Technical data
4.1 Basic data
Type KL 1500-3, T, S
Number of axes 1
Rated travel Min. rated travel = 1,000 mm
Max. rated travel = 30,000 mm
(longer rated travels available on re-
quest)
Gradation of rated travel 500 mm
Velocity vmax = 1.45 m/s, KL 1500-3
vmax = 1.89 m/s, KL 1500-3 T
vmax = 2.35 m/s, KL 1500-3 S
Repeatability (ISO 9283) ±0.02 mm
Mass of carriage m = 440 kg
Mass of beam assy m = 345 kg/m
Payload Robot with supplementary loads,
see robot
Max. permissible payload 2,000 kg, KL 1500-3
3,800 kg, KL 1500-3 T
3,800 kg, KL 1500-3 S
Number of chemical anchors
per mounting base
6x M16, with Dynamic Set
10x M16, with Dynamic Set
4x M20, without Dynamic Set (op-
tional)
8x M20, without Dynamic Set (op-
tional)
Loads acting on the foundation see (>>> 6.2.1 "Loads acting on the
foundation" page 42)
Mounting base dimensions see (>>> 6.2 "Foundation data"
page 42)
Color Carriage: KUKA orange 2567
Beam: RAL 7022
Protection classification Motor and gear unit connected (ac-
cording to EN 60729) IP 64.
Linear unit ready for operation, with
connecting cables plugged in (ac-
cording to EN 60729) IP 64.
Sound level < 75 dB (A) outside the working en-
velope (moving KL with moving ro-
bot)
< 69 dB (A) outside the working en-
velope (moving KL without robot)
Permissible angle of inclination 0º
Mounting position Floor
Number of carriages max. 4 carriages
Valid for robots KR 30 to KR 125, KR 150, KR 200,
KR 360, KR 500
KR 150 to KR 270 (Series 2000)
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KL 1500-3; KL 1500-3 T; KL 1500-3 S
Ambient temper-
ature
4.2 Principal dimensions
Linear unit
Pedestals (for robots) min. 200 mm high
max. 800 mm high
gradation 100 mm
Order-specific technical data The “Order-specific technical data”
can be found in the section
(>>> 4.4 "Order-specific technical
data" page 24).
Operation 283 K to 328 K (+10 °C to +55 °C)
283 K to 288 K (+10 °C to +15 °C) At these tem-
peratures the robot may have to be warmed up
before normal operation. Other temperature
limits available on request.
Operation with Safe
RDC
283 K to 323 K (+10 °C to +50 °C)
Storage and transpor-
tation
233 K to 333 K (-40 °C to +60 °C)
Humidity rating Humidity class
EN 60204/4.4.4 F
Fig. 4-1: Principal dimensions, cross-section
This manual suits for next models
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