Kuka KR QUANTEC extra User manual

Robots
KR QUANTEC extra
With F and C Variants
Specification
KUKA Roboter GmbH
Issued: 18.06.2015
Version: Spez KR QUANTEC extra V6
KR QUANTEC
extra

KR QUANTEC extra
2 / 127 Issued: 18.06.2015 Version: Spez KR QUANTEC extra V6
© Copyright 2015
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 Spez KR QUANTEC extra (PDF) en
Book structure: Spez KR QUANTEC extra V5.1
Version: Spez KR QUANTEC extra V6

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Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 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 Overview of the robot system .................................................................................... 11
3.2 Description of the manipulator ................................................................................... 11
4 Technical data .............................................................................................. 15
4.1 Basic data ..................................................................................................................15
4.2 Axis data .................................................................................................................... 17
4.3 Payloads ....................................................................................................................27
4.4 Foundation loads ....................................................................................................... 37
4.5 Transport dimensions ................................................................................................ 39
4.6 Plates and labels ........................................................................................................ 39
4.7 Stopping distances and times .................................................................................... 41
4.7.1 General information .............................................................................................. 41
4.7.2 Terms used ........................................................................................................... 42
4.7.3 Stopping distances and times, KR 210 R2700 extra ............................................ 43
4.7.3.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 43
4.7.3.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 44
4.7.3.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 46
4.7.3.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 48
4.7.4 Stopping distances and times, KR 180 R2500 extra ............................................ 48
4.7.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 48
4.7.4.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 49
4.7.4.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 51
4.7.4.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 53
4.7.5 Stopping distances and times, KR 180 R2500 extra C ......................................... 53
4.7.5.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 53
4.7.5.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 54
4.7.5.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 56
4.7.5.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 58
4.7.6 Stopping distances and times, KR 150 R2700 extra ............................................ 58
4.7.6.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 58
4.7.6.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 59
4.7.6.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 61
4.7.6.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 63
4.7.7 Stopping distances and times, KR 150 R2700 extra C ......................................... 63
4.7.7.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 63
4.7.7.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 64
4.7.7.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 66
4.7.7.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 68
4.7.8 Stopping distances and times, KR 120 R2900 extra ............................................ 68
Contents

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4.7.8.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 68
4.7.8.2 Stopping distances and stopping times for STOP 1, axis 1 ............................ 69
4.7.8.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 71
4.7.8.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 73
4.7.9 Stopping distances and times, KR 120 R2900 extra C ........................................ 73
4.7.9.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 73
4.7.9.2 Stopping distances and stopping times for STOP 1, axis 1 ............................ 74
4.7.9.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 76
4.7.9.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 78
4.7.10 Stopping distances and times, KR 90 R3100 extra .............................................. 78
4.7.10.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 78
4.7.10.2 Stopping distances and stopping times for STOP 1, axis 1 ............................ 79
4.7.10.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 81
4.7.10.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 83
4.7.11 Stopping distances and times, KR 90 R3100 extra C .......................................... 83
4.7.11.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 83
4.7.11.2 Stopping distances and stopping times for STOP 1, axis 1 ............................ 84
4.7.11.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 86
4.7.11.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 88
5 Safety ............................................................................................................ 89
5.1 General ...................................................................................................................... 89
5.1.1 Liability .................................................................................................................89
5.1.2 Intended use of the industrial robot ...................................................................... 90
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 90
5.1.4 Terms used .......................................................................................................... 91
5.2 Personnel .................................................................................................................. 91
5.3 Workspace, safety zone and danger zone ................................................................ 92
5.4 Overview of protective equipment ............................................................................. 93
5.4.1 Mechanical end stops ........................................................................................... 93
5.4.2 Mechanical axis range limitation (optional) ........................................................... 93
5.4.3 Axis range monitoring (optional) ........................................................................... 93
5.4.4 Options for moving the manipulator without drive energy .................................... 94
5.4.5 Labeling on the industrial robot ............................................................................ 94
5.5 Safety measures ........................................................................................................ 95
5.5.1 General safety measures ..................................................................................... 95
5.5.2 Transportation ...................................................................................................... 96
5.5.3 Start-up and recommissioning .............................................................................. 96
5.5.4 Manual mode ........................................................................................................ 98
5.5.5 Automatic mode ................................................................................................... 98
5.5.6 Maintenance and repair ........................................................................................ 99
5.5.7 Decommissioning, storage and disposal .............................................................. 100
5.6 Applied norms and regulations .................................................................................. 100
6 Planning ........................................................................................................ 103
6.1 Mounting base with centering .................................................................................... 103
6.2 Machine frame mounting ........................................................................................... 105
6.3 Connecting cables and interfaces ............................................................................. 106
7 Transportation ............................................................................................. 109

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7.1 Transporting the robot ................................................................................................ 109
8 Options ......................................................................................................... 113
8.1 Mounting flange, adapter (optional) ........................................................................... 113
8.2 Control cable for single axis (optional) ....................................................................... 114
8.3 Release device (optional) .......................................................................................... 114
9 KUKA Service .............................................................................................. 115
9.1 Requesting support .................................................................................................... 115
9.2 KUKA Customer Support ........................................................................................... 115
Index ............................................................................................................. 123

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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 System Software
Instructions for 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:
Hints These notices serve to make your work easier or contain references to further
information.
t
t
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.

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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 misuse
and is not allowed. 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
2
s
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.
Deviations from the operating conditions specified in the
technical data or the use of special functions or applica-
tions can lead to premature wear. KUKA Roboter GmbH must be consulted.
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 QUANTEC extra product family comprises the variants:
KR 210 R2700 extra
KR 180 R2500 extra
KR 150 R2700 extra
KR 120 R2900 extra
KR 90 R3100 extra
With the exception of the KR 210 R2700 extra, the robots are available as both
F-HP variants (foundry) and C variants (ceiling-mounted).
An industrial robot of this type comprises the following components:
Manipulator
Robot controller
Connecting cables
KCP teach pendant (KUKA smartPAD)
Software
Options, accessories
3.2 Description of the manipulator
Overview The manipulators (= robot arm and electrical installations) (>>> Fig. 3-2 ) of
the variants are designed as 6-axis jointed-arm kinematic systems. They con-
sist of the following principal components:
t
s
Fig. 3-1: Example of a robot system
1 Manipulator 3 Robot controller
2 Connecting cables 4 KUKA smartPAD
teach pendant

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In-line wrist
Arm
Link arm
Rotating column
Base frame
Counterbalancing system
Electrical installations
In-line wrist The robot is fitted with a 3-axis in-line wrist. The in-line wrist contains axes 4,
5 and 6. The motor of axis 6 is located directly on the wrist, inside the arm. It
drives the wrist directly, while for axes 4 and 5 the drive comes from the rear
of the arm via connecting shafts. For attaching end effectors (tools), the in-line
wrist has a mounting flange. The mounting flange conforms, with minimal de-
viations, to ISO9409-1: 2004 and meets the requirements of IP65.
Additional measures have been taken to enable in-line wrists of the F-HP vari-
ants to meet higher specifications in terms of resistance to temperature, dust
and corrosion. F-HP variant in-line wrists meet the requirements of IP67.
Arm The arm is the link between the in-line wrist and the link arm. It houses the mo-
tors of wrist axes 4 and 5. The arm is driven by the motor of axis 3. The max-
imum permissible swivel angle is mechanically limited by a stop for each
direction, plus and minus. The associated buffers are attached to the arm.
There is an interface on the arm with 4 holes for fastening supplementary
loads.
The arms of the F-HP variants are pressurized to prevent penetration of mois-
ture and dust. The required compressed air is supplied via a hose in the cable
harness. The pressure regulator for this is installed in the push-in module for
the electrical installations.
Fig. 3-2: Main assemblies of the manipulator
1 In-line wrist 5 Base frame
2 Arm 6 Rotating column
3 Counterbalancing system 7 Link arm
4 Electrical installations

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3 Product description
Link arm The link arm is the assembly located between the arm and the rotating column.
It consists of the link arm body with the buffers for axis 2. In combination with
the arm, there are three different lengths of link arm available to obtain the
specified reach.
Rotating column 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. It is screwed to the mounting base.
The flexible tube for the electrical installations is fastened to the base frame.
Also located on the base frame is the interface for the motor and data cable
and the energy supply system.
Counterbal-
ancing system
The counterbalancing system is installed between the rotating column and the
link arm and serves to minimize the moments generated about axis 2 when the
robot is in motion and at rest. A closed, hydropneumatic system is used. The
system consists of two accumulators, a hydraulic cylinder with associated hos-
es, a pressure gauge and a bursting disc as a safety element to protect against
overload. The accumulators are classified below category I, fluid group 2, of
the Pressure Equipment Directive. Different variants of the counterbalancing
system are used for floor and ceiling-mounted robots and for the F variants.
The mode of operation is reversed for ceiling-mounted robots, i.e. the piston
rod pushes against the link arm.
Electrical
installations
The electrical installations include all the motor and data cables for the motors
of axes 1 to 6. All connections are implemented as connectors in order to en-
able the motors to be exchanged quickly and reliably. The electrical installa-
tions also include the RDC box and the multi-function housing (MFH). The
RDC box is located in the rotating column. The MFH and the connector for the
data cables are mounted on the robot base frame. The connecting cables from
the robot controller are connected here by means of connectors. The electrical
installations also include a protective circuit .
Options The robot can be fitted and operated with various options, such as energy sup-
ply systems for axes 1 to 3, energy supply systems for axes 3 to 6, or working
range limitation systems for A1. The options are described in separate docu-
mentation.

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4 Technical data
4 Technical data
4.1 Basic data
Basic data
4
T
t
Type KR 210 R2700 extra
KR 180 R2500 extra
KR 150 R2700 extra
KR 120 R2900 extra
KR 90 R3100 extra
Number of axes 6
Volume of working
envelope KR 210 R2700 extra 55 m3
KR 180 R2500 extra 41 m3
KR 180 R2500 C extra 41 m3
KR 150 R2700 extra 55 m3
KR 150 R2700 C extra 55 m3
KR 120 R2900 extra 66 m3
KR 120 R2900 C extra 66 m3
KR 90 R3100 extra 84 m3
KR 90 R3100 C extra 84 m3
Pose repeatability
(ISO 9283) ±0.06 mm
Working envelope ref-
erence point
Intersection of axes 4 and 5
Weight KR 210 R2700 extra approx. 1068 kg
KR 180 R2500 extra approx. 1059 kg
KR 150 R2700 extra approx. 1068 kg
KR 120 R2900 extra approx. 1084 kg
KR 90 R3100 extra approx. 1092 kg
Principal dynamic
loads
See “Foundation loads”
Protection rating of the
robot
IP65
Ready for operation, with connecting cables
plugged in (according to EN 60529)
Protection rating of the
F-HP in-line wrist
IP67
Sound level < 75 dB (A) outside the working envelope
Mounting position Floor
Permissible angle of inclination ≤5º
Ceiling
No angle of inclination permissible
Surface finish, paint-
work
Base frame, counterbalancing system and
motors: black (RAL 9005); moving parts: KUKA
orange 2567

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Foundry robots
Ambient temper-
ature
Connecting
cables
Overpressure in the
arm
0.01 MPa (0.1 bar)
Compressed air Free of oil and water
Class 4 in accordance with ISO 8573-1
Compressed air sup-
ply line
Air line in the cable set
Air consumption 0.1 m3/h
Air line connection Quick Star push-in fitting for hose PLN-6x1,
black
Pressure regulator
connection
R 1/8", internal thread
Input pressure 0.1 - 1.2 MPa (1 - 12 bar)
Pressure regulator 0.005 - 0.07 MPa (0.05 - 0.7 bar)
Manometer range 0.0 - 0.1 MPa (0.0 - 1.0 bar)
Filter gauge 25 - 30 µm
Thermal
loading
10 s/min at 353 K (180 °C)
Resistance Increased resistance to dust, lubricants, coolants
and water vapor.
Special paint finish on
wrist
Heat-resistant and heat-reflecting silver paint fin-
ish on the in-line wrist.
Special paint finish on
the robot
Special paint finish on the entire robot, and an
additional protective clear coat.
Other ambient condi-
tions
KUKA Roboter GmbH must be consulted if the
robot is to be used under other ambient condi-
tions.
Operation 283 K to 328 K (+100 °C to +55 °C)
Storage and transpor-
tation
233 K to 333 K (-40 °C to +60 °C)
Start-up In the case of start-up in the range of 278 K to
288 K (+5 °C to +15 °C), the robot may have to
be warmed up. Other temperature limits available
on request.
Ambient conditions DIN EN 60721-3-3,
Class 3K3
Cable designation Connector designa-
tion
robot controller - ro-
bot
Interface with robot
Motor cable X20 - X30 Harting connectors at
both ends
Data cable X21 - X31 Rectangular connec-
tor
at both ends
Ground conductor /
equipotential bonding
16 mm2
(can be ordered as an
option)
M8 ring cable lug at
both ends

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4 Technical data
For detailed specifications of the connecting cables, see “Description of the
connecting cables”.
4.2 Axis data
Axis data, KR 210
R2700 extra
Axis data, KR 180
R2500 extra
Axis data, KR 180
R2500 C extra
Axis data, KR 150
R2700 extra
Cable lengths
Standard 7 m, 15 m, 25 m, 35 m, 50 m
Minimum bending radius 5x D
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 112°/s
4 +/-350° 179°/s
5 +/-125° 172°/s
6 +/-350° 219°/s
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 179°/s
5 +/-125° 172°/s
6 +/-350° 219°/s
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -6° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 179°/s
5 +/-125° 172°/s
6 +/-350° 219°/s
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 179°/s
5 +/-125° 172°/s
6 +/-350° 219°/s

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Axis data, KR 150
R2700 C extra
Axis data, KR 120
R2900 extra
Axis data, KR 120
R2900 C extra
Axis data, KR 90
R3100
extra
Axis data, KR 90
R3100 C
extra
Working
envelope
The following diagrams show the shape and size of the working envelopes for
the “extra” variants.
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 179°/s
5 +/-125° 172°/s
6 +/-350° 219°/s
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 292°/s
5 +/-125° 258°/s
6 +/-350° 284°/s
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 292°/s
5 +/-125° 258°/s
6 +/-350° 284°/s
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 292°/s
5 +/-125° 258°/s
6 +/-350° 284°/s
Axis Range of motion, software-
limited Speed with rated payload
1 +/-185° 123°/s
2 -5° to -140° 115°/s
3 +155° to -120° 120°/s
4 +/-350° 292°/s
5 +/-125° 258°/s
6 +/-350° 284°/s

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4 Technical data
The reference point for the working envelope is the intersection of axes 4 and
5.
Fig. 4-1: Working envelope, KR 210 R2700 extra

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* Valid for F-HP in-line wrist
Fig. 4-2: Working envelope, KR 180 R2500 extra