Kuka KR AGILUS sixx User manual

Robots
KR AGILUS sixx
With W and C Variants
Assembly Instructions
KUKA Roboter GmbH
Issued: 28.03.2013
Version: MA KR AGILUS sixx V8 en (PDF)

KR AGILUS sixx
2 / 141 Issued: 28.03.2013 Version: MA KR AGILUS sixx V8 en (PDF)
© Copyright 2013
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
Publication: Pub MA KR AGILUS sixx (PDF) en
Bookstructure: MA KR AGILUS sixx V6.1
Version: MA KR AGILUS sixx V8 en (PDF)

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Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Terms used ................................................................................................................ 7
2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9
3 Product description ..................................................................................... 11
3.1 Overview of the robot system .................................................................................... 11
3.2 Description of the manipulator ................................................................................... 11
4 Technical data .............................................................................................. 15
4.1 Basic data, KR 6 sixx ................................................................................................. 16
4.2 Axis data, KR 6 sixx ................................................................................................... 17
4.3 Payloads, KR 6 sixx ................................................................................................... 22
4.4 Mounting base data, KR 6 sixx .................................................................................. 26
4.5 Basic data, KR 10 sixx ............................................................................................... 27
4.6 Axis data, KR 10 sixx ................................................................................................. 28
4.7 Payloads, KR 10 sixx ................................................................................................. 37
4.8 Mounting base data, KR 10 sixx ................................................................................ 43
4.9 Plates and labels ........................................................................................................ 44
4.10 Stopping distances and times .................................................................................... 45
4.10.1 General information .............................................................................................. 45
4.10.2 Terms used ........................................................................................................... 46
4.10.3 Stopping distances and times, KR 6 R900 sixx ................................................... 47
4.10.3.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 47
4.10.3.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 48
4.10.3.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 50
4.10.3.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 52
4.10.4 Stopping distances and times, KR 6 R900 sixx W ................................................ 52
4.10.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 52
4.10.4.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 54
4.10.4.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 56
4.10.4.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 58
4.10.5 Stopping distances and times, KR 10 R900 sixx and KR 10 R1100 sixx ............. 58
4.10.5.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 58
4.10.5.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 60
4.10.5.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 62
4.10.5.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 64
4.10.6 Stopping distances and times, KR 10 R900 sixx W and KR 10 R1100 sixx W .... 64
4.10.6.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 64
4.10.6.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 66
4.10.6.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 68
4.10.6.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 70
5 Safety ............................................................................................................ 71
5.1 General ...................................................................................................................... 71
Contents

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5.1.1 Liability .................................................................................................................71
5.1.2 Intended use of the industrial robot ...................................................................... 72
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 72
5.1.4 Terms used .......................................................................................................... 73
5.2 Personnel .................................................................................................................. 74
5.3 Workspace, safety zone and danger zone ................................................................ 75
5.4 Overview of protective equipment ............................................................................. 76
5.4.1 Mechanical end stops ........................................................................................... 76
5.4.2 Mechanical axis range limitation (optional) ........................................................... 76
5.4.3 Axis range monitoring (optional) ........................................................................... 77
5.4.4 Options for moving the manipulator without the robot controller .......................... 77
5.4.5 Labeling on the industrial robot ............................................................................ 78
5.5 Safety measures ........................................................................................................ 79
5.5.1 General safety measures ..................................................................................... 79
5.5.2 Transportation ...................................................................................................... 80
5.5.3 Start-up and recommissioning .............................................................................. 80
5.5.4 Manual mode ........................................................................................................ 81
5.5.5 Automatic mode ................................................................................................... 82
5.5.6 Maintenance and repair ........................................................................................ 82
5.5.7 Decommissioning, storage and disposal .............................................................. 84
5.6 Applied norms and regulations .................................................................................. 84
6 Planning ........................................................................................................ 87
6.1 Mounting base ........................................................................................................... 87
6.2 Machine frame mounting ........................................................................................... 89
6.3 Connecting cables and interfaces ............................................................................. 90
6.4 Customer interfaces .................................................................................................. 91
7 Transportation ............................................................................................. 97
7.1 Transporting the manipulator ..................................................................................... 97
8 Start-up and recommissioning ................................................................... 101
8.1 Installing the mounting base ...................................................................................... 101
8.2 Installing the machine frame mounting assembly ...................................................... 102
8.3 Installing a floor-mounted robot ................................................................................. 103
8.4 Installing a wall-mounted robot .................................................................................. 104
8.5 Installing a ceiling-mounted robot .............................................................................. 108
8.6 Description of the connecting cables ......................................................................... 112
8.7 Moving the manipulator without the robot controller .................................................. 118
9 Appendix ...................................................................................................... 119
9.1 Tightening torque ....................................................................................................... 119
9.2 Safety data sheets ..................................................................................................... 119
9.2.1 Safety data sheet for Flexolub®-A1 lubricant ....................................................... 119
9.2.1.1 Designation of substance/formulation and manufacturer ................................ 119
9.2.1.2 Composition / Information about the components ........................................... 119
9.2.1.3 Possible hazards ............................................................................................. 120
9.2.1.4 First aid measures ........................................................................................... 120
9.2.1.5 Fire-fighting measures ..................................................................................... 120
9.2.1.6 Measures after unintended release ................................................................. 120

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9.2.1.7 Handling and storage ....................................................................................... 121
9.2.1.8 Exposure limits and personal protective equipment ........................................ 121
9.2.1.9 Physical and chemical properties .................................................................... 121
9.2.1.10 Stability and reactivity ...................................................................................... 122
9.2.1.11 Toxicological information ................................................................................. 122
9.2.1.12 Ecological information ...................................................................................... 122
9.2.1.13 Disposal information ........................................................................................ 122
9.2.1.14 Transport information ....................................................................................... 122
9.2.1.15 Regulations ...................................................................................................... 123
9.2.1.16 Other information ............................................................................................. 123
9.2.2 Safety data sheet for OBEEN FS 2 lubricant ........................................................ 123
9.2.2.1 Designation of substance/formulation and manufacturer ................................ 123
9.2.2.2 Composition / Information about the components ........................................... 124
9.2.2.3 Possible hazards ............................................................................................. 124
9.2.2.4 First aid measures ........................................................................................... 124
9.2.2.5 Fire-fighting measures ..................................................................................... 125
9.2.2.6 Measures after unintended release ................................................................. 125
9.2.2.7 Handling and storage ....................................................................................... 125
9.2.2.8 Exposure limits and personal protective equipment ........................................ 125
9.2.2.9 Physical and chemical properties .................................................................... 126
9.2.2.10 Stability and reactivity ...................................................................................... 126
9.2.2.11 Toxicological information ................................................................................. 126
9.2.2.12 Ecological information ...................................................................................... 126
9.2.2.13 Disposal information ........................................................................................ 127
9.2.2.14 Transport information ....................................................................................... 127
9.2.2.15 Regulations ...................................................................................................... 127
9.2.2.16 Other information ............................................................................................. 128
10 KUKA Service .............................................................................................. 131
10.1 Requesting support .................................................................................................... 131
10.2 KUKA Customer Support ........................................................................................... 131
Index ............................................................................................................. 139

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1 Introduction
1Introduction
1.1 Industrial robot documentation
The industrial robot documentation consists of the following parts:
Documentation for the manipulator
Documentation for the robot controller
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 These warnings are relevant to safety and must be observed.
This warning draws attention to procedures which serve to prevent or remedy
emergencies or malfunctions:
Notes These hints serve to make your work easier or contain references to further
information.
1.3 Terms used
These warnings mean that it is certain or highly probable
that death or severe injuries will occur, if no precautions
are taken.
These warnings mean that death or severe injuries may
occur, if no precautions are taken.
These warnings mean that minor injuries may occur, if
no precautions are taken.
These warnings mean that damage to property may oc-
cur, if no precautions are taken.
These warnings contain references to safety-relevant information or
general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.
Procedures marked with this warning must be followed
exactly.
Tip to make your work easier or reference to further information.
Term Description
MEMD Micro Electronic Mastering Device
KL KUKA linear unit

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RDC Resolver Digital Converter
smartPAD The smartPAD teach pendent has all the opera-
tor control and display functions required for
operating and programming the industrial robot.
Term Description

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2 Purpose
2Purpose
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 industrial robot is intended for handling tools and fixtures, or for process-
ing or transferring components or products. Use is only permitted under the
specified environmental conditions.
Misuse Any use or application deviating from the intended use is deemed to be imper-
missible 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
Use in underground mining
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 program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.
Changing the structure of the manipulator, 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 enti-
tlements.
The robot system is an integral part of a complete system and may
only be operated in a CE-compliant system.

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3 Product description
3 Product description
3.1 Overview of the robot system
A robot system (>>> Fig. 3-1 ) comprises all the assemblies of an industrial
robot, including the manipulator (mechanical system and electrical installa-
tions), control cabinet, connecting cables, end effector (tool) and other equip-
ment. The KR AGILUS product family consists of the following type:
KR 6 R900 sixx
KR 10 R900 sixx
KR 10 R1100 sixx
The robots are also available as W and C variants (wall-mounted and ceiling-
mounted versions).
An industrial robot of this type comprises the following components:
Manipulator
Robot controller
smartPAD teach pendant
Connecting cables
Software
Options, accessories
3.2 Description of the manipulator
Overview The manipulators are 6-axis jointed-arm manipulators made of cast light alloy.
Each axis is fitted with a brake. All motor units and current-carrying cables are
protected against dirt and moisture beneath screwed-on cover plates.
Fig. 3-1: Example of an industrial robot
1 Manipulator
2 smartPAD teach pendant
3 Connecting cable, smartPAD
4 Robot controller
5 Connecting cable, data cable
6 Connecting cable, motor cable

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The robot consists of the following principal components:
In-line wrist
Arm
Link arm
Rotating column
Base frame
Electrical installations
In-line wrist
A4, A5, A6
The robot is fitted with a 3-axis in-line wrist. The in-line wrist consists of axes
4, 5 and 6.
There are three 4/2-way solenoid valves and a CAT5 data cable in the in-line
wrist that can be used for controlling tools.
The in-line wrist also accommodates the 10-contact circular connector of the
wrist I/O cable and interface A4 for the energy supply system.
Arm
A3
The arm is the link between the in-line wrist and the link arm. The arm is driven
by the motor of axis 3.
Link arm
A2
The link arm is the assembly located between the arm and the rotating column.
It houses the motor and gear unit of axis 2. The supply lines of the energy sup-
ply system and the cable set for axes 2 to 6 are routed through the link arm.
Rotating column
A1
The rotating column houses the motors of axes 1 and 2. The rotational motion
of axis 1 is performed by the rotating column. This is screwed to the base
frame via the gear unit of axis 1 and is driven by a motor in the rotating column.
The link arm is also mounted in the rotating column.
Base frame The base frame is the base of the robot. Interface A1 is located at the rear of
the base frame. It constitutes the interface for the connecting cables between
the robot, the controller and the energy supply system.
Electrical installa-
tions
The electrical installations include all the motor and control cables for the mo-
tors of axes 1 to 6. All connections are pluggable. The electrical installations
also include the RDC box, which is integrated into the robot. The connectors
Fig. 3-2: Principal components
1 In-line wrist 4 Rotating column
2 Arm 5 Electrical installations
3 Link arm 6 Base frame

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3 Product description
for the motor and data cables are mounted on the robot base frame. The con-
necting cables from the robot controller are connected here by means of con-
nectors. The electrical installations also include a protective circuit.
Options The robot can be fitted and operated with various options, e.g. working range
limitation A1 or brake release device. The option is described in separate doc-
umentation.

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4 Technical data
4 Technical data
The technical data for the individual robot types can be found in the following
sections:
Robot Technical data
KR 6 sixx
KR 6 R900 sixx
KR 6 R900 sixx
KR 6 R900 sixx W
KR 6 R900 sixx C
Basic data
(>>> 4.1 "Basic data, KR 6 sixx" Page 16)
Axis data
(>>> 4.2 "Axis data, KR 6 sixx" Page 17)
Payloads
(>>> 4.3 "Payloads, KR 6 sixx" Page 22)
Foundation data
(>>> 4.4 "Mounting base data, KR 6 sixx"
Page 26)
Plates and labels
(>>> 4.9 "Plates and labels" Page 44)
Stopping distances
(>>> 4.10.3 "Stopping distances and
times, KR 6 R900 sixx " Page 47)
(>>> 4.10.4 "Stopping distances and
times, KR 6 R900 sixx W" Page 52)
KR 10 sixx
KR 10 R900 sixx
KR 10 R900 sixx
KR 10 R900 sixx W
KR 10 R900 sixx C
KR 10 R1100 sixx
KR 10 R1100 sixx
KR 10 R1100 sixx W
KR 10 R1100 sixx C
Basic data
(>>> 4.5 "Basic data, KR 10 sixx" Page 27)
Axis data
(>>> 4.6 "Axis data, KR 10 sixx" Page 28)
Payloads
(>>> 4.7 "Payloads, KR 10 sixx" Page 37)
Foundation data
(>>> 4.8 "Mounting base data, KR 10 sixx"
Page 43)
Plates and labels
(>>> 4.9 "Plates and labels" Page 44)
Stopping distances
(>>> 4.10.5 "Stopping distances and
times, KR 10 R900 sixx and KR 10 R1100
sixx" Page 58)
(>>> 4.10.6 "Stopping distances and
times, KR 10 R900 sixx W and KR 10
R1100 sixx W" Page 64)

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4.1 Basic data, KR 6 sixx
Basic data
Ambient condi-
tions
The maintenance intervals and the specified service life are based on typical
gear unit temperatures and axis motions. If special functions or applications
result in atypical gear unit temperatures or axis motions, this can lead to in-
creased wear. In this case, the maintenance intervals or service life may be
shortened. If you have any questions, please contact KUKA Customer Sup-
port.
Type KR 6 R900 sixx
KR 6 R900 sixx W
KR 6 R900 sixx C
Number of axes 6
Volume of working
envelope KR 6 R900 sixx: 2.85 m3
KR 6 R900 sixx W: 2.85 m3
KR 6 R900 sixx C: 2.85 m3
Pose repeatability
(ISO 9283)
±0.03 mm
KR 6 R900 sixx: ±0.03 mm
KR 6 R900 sixx W: ±0.03 mm
KR 6 R900 sixx C: ±0.03 mm
Working envelope ref-
erence point
Intersection of axes 4 and 5
Weight approx. 52 kg
KR 6 R900 sixx: approx. 52 kg
KR 6 R900 sixx W: approx. 52 kg
KR 6 R900 sixx C: approx. 52 kg
Principal dynamic
loads
See Loads acting on the foundation
Protection classifica-
tion of the robot
IP 54
ready for operation, with connecting cables
plugged in (according to EN 60529)
Protection classifica-
tion of the in-line wrist
IP 54
Sound level < 70 dB (A) outside the working envelope
Mounting position Floor, wall, ceiling
Surface finish, paint-
work
Base (stationary) and covers on link arm: black
(RAL 9011); moving parts: KUKA orange 2567
Operation 278 K to 318 K (+5 °C to +45 °C)
No condensation permissible.
Storage and transpor-
tation
-40 °C to +60 °C (233 K to 333 K)
Ambient conditions Relative air humidity ≤90%
DIN EN 60721-3-3,
Class 3K3
Altitude up to 1000 m above mean sea level with no
reduction in power
1000 m ... 4000 m above mean sea level with
a reduction in power of 5%/1000 m

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4 Technical data
Connecting
cables
Only resolvers can be connected to the connections XP7.1 and XP8.1.
For detailed specifications of the connecting cables, see (>>> 8.6 "De-
scription of the connecting cables" Page 112).
4.2 Axis data, KR 6 sixx
Axis data The following axis data are valid for the robots:
KR 6 R900 sixx
KR 6 R900 sixx W
KR 6 R900 sixx C
The direction of motion and the arrangement of the individual axes may be not-
ed from the diagram (>>> Fig. 4-1 ).
Cable designation Connector designation
robot controller -
robot
Interface with
robot
Motor cable X20 - X30 Han Yellock 30
Data cable X21 - X31 Han Q12
CAT5 data cable
(can be ordered as an
option)
X65/X66 - XPN1 M12 connector
Connecting cable, exter-
nal axes A7 and A8
(can be ordered as an
option)
XP7 - XP7.1
XP8 - XP8.1
Connector M17
in each case
Ground conductor, equi-
potential bonding
(can be ordered as an
option)
Ring cable lug
M4
Cable lengths
Standard 4 m
Option 1 m, 7 m, 15 m, 25 m
Axis Range of motion, software-
limited
Speed with
rated payload
1 +/-170° 360 °/s
2 +45° to -190° 300 °/s
3 +156° to -120° 360 °/s
4 +/-185° 381 °/s
5 +/-120° 388 °/s
6 +/-350° 615 °/s

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Working
envelope
The following diagram (>>> Fig. 4-2 ) shows the shape and size of the work-
ing envelope for the robot:
KR 6 R900 sixx
Fig. 4-1: Direction of rotation of robot axes

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4 Technical data
The following diagram (>>> Fig. 4-3 ) shows the shape and size of the work-
ing envelope for the robot:
KR 6 R900 sixx W
Fig. 4-2: Working envelope, KR 6 R900 sixx

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The following diagram (>>> Fig. 4-4 ) shows the shape and size of the work-
ing envelope for the robot:
Fig. 4-3: Working envelope, KR 6 R900 sixx W