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Positioner

KUKA Posiflex KPF5-V2H2H500

Specification

KUKA Roboter GmbH

Issued: 06.12.2011

Version: Spez KPF5-V2H2H500 V3 en




2 / 57 Issued: 06.12.2011 Version: Spez KPF5-V2H2H500 V3 en

© Copyright 2011

KUKA Roboter GmbH

Zugspitzstraße 140

D-86165 Augsburg

Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties withoutthe express permission of KUKA Roboter GmbH.

Other functions not described in this documentation may be operable in the controller. The user hasno 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 softwaredescribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able toguarantee 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 KPF5-V2H2H500 (PDF) en

Bookstructure: Spez KPF5-V2H2H500 V3.1

Version: Spez KPF5-V2H2H500 V3 en



3 / 57Issued: 06.12.2011 Version: Spez KPF5-V2H2H500 V3 en

Contents

1 Introduction .................................................................................................. 5

1.1 Representation of warnings and notes ...................................................................... 5

1.2 Terms used ................................................................................................................ 5

2 Purpose ........................................................................................................ 7

2.1 Intended use .............................................................................................................. 7

2.2 Target group .............................................................................................................. 7

3 Product description ..................................................................................... 9

3.1 Overview .................................................................................................................... 9

3.2 Description of the positioner ...................................................................................... 9

3.3 Control and integration ............................................................................................... 10

3.4 Connecting cables ..................................................................................................... 11

3.5 Description of the electrical installations .................................................................... 12

4 Technical data .............................................................................................. 15

4.1 Basic data .................................................................................................................. 15

4.2 Axis data .................................................................................................................... 15

4.3 Payloads .................................................................................................................... 17

4.4 Loads acting on the mounting base ........................................................................... 17

4.5 Additional data ........................................................................................................... 18

4.6 Plates and labels ........................................................................................................ 18

5 Safety ............................................................................................................ 21

5.1 General ...................................................................................................................... 21

5.1.1 Liability .................................................................................................................. 215.1.2 Intended use of the industrial robot ...................................................................... 22

5.1.3 EC declaration of conformity and declaration of incorporation ............................. 22

5.1.4 Terms used ........................................................................................................... 23

5.2 Personnel ................................................................................................................... 23

5.3 Workspace, safety zone and danger zone ................................................................. 25

5.4 Overview of protective equipment .............................................................................. 25

5.4.1 Mechanical end stops ........................................................................................... 26

5.4.2 Mechanical axis range limitation (optional) ........................................................... 26

5.4.3 Axis range monitoring (optional) ........................................................................... 26

5.4.4 Release device (optional) ..................................................................................... 265.4.5 Labeling on the industrial robot ............................................................................. 27

5.5 Safety measures ........................................................................................................ 27

5.5.1 General safety measures ...................................................................................... 27

5.5.2 Transportation ....................................................................................................... 29

5.5.3 Start-up and recommissioning .............................................................................. 29

5.5.4 Manual mode ........................................................................................................ 30

5.5.5 Automatic mode .................................................................................................... 31

5.5.6 Maintenance and repair ........................................................................................ 31

5.5.7 Decommissioning, storage and disposal .............................................................. 33

5.6 Applied norms and regulations .................................................................................. 33

6 Planning ....................................................................................................... 35

Contents





6.1 KPF5-V2H2H500 mounting base with centering ....................................................... 35

6.2 KPF5-V2H2H500 machine frame mounting assembly .............................................. 36

6.3 Dimensions of face plates ......................................................................................... 37

7 Transportation ............................................................................................. 41

7.1 Transportation ........................................................................................................... 41

8 Appendix ...................................................................................................... 45

8.1 Tightening torque ....................................................................................................... 45

9 KUKA Service ............................................................................................... 47

9.1 Requesting support ................................................................................................... 47

9.2 KUKA Customer Support ........................................................................................... 47

Index ............................................................................................................. 55




1 Introduction

1 Introduction

1.1 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

Hints These hints serve to make your work easier or contain references to further information.

1.2 Terms used

These warnings mean that it is certain or highly probablethat death or severe physical injury will occur, if no pre-cautions are taken.

These warnings mean that death or severe physical inju-ry may occur, if no precautions are taken.

These warnings mean that minor physical 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 individualhazards or individual precautionary measures.

Tip to make your work easier or reference to further information.

Term Description

Axis range Range of an axis, in degrees, within which therobot/positioner may move. The axis range mustbe defined for each axis that is to be monitored.

Drive unit A combination of motor and gear unit.

Workspace The robot/positioner is allowed to move within itsworkspace. The workspace is derived from theindividual axis ranges.

Braking distance The braking distance is the distance covered bythe robot/positioner after the stop function hasbeen triggered and before the robot comes to astandstill.

CE mark

(CE mark)

The safety requirements of all relevant EC direc-tives have been met. All prescribed conformityassessment procedures have been carried out.

Release device The release device can be used to move thepositioner mechanically after an accident or mal-function.

Danger zone The danger zone consists of the workspace andthe braking distances.

KCP The KCP (KUKA Control Panel) teach pendanthas all the functions required for operating andprogramming the industrial robot.





KUKA positioner KUKA positioning system is a kinematic systemthat is controlled by the robot controller as anexternal axis. The shorter term “positioner” isused in the documentation.

Manipulator The robot arm and the associated electricalinstallations

RDC The RDC (Resolver Digital Converter) consti-tutes the connection between the motors of therobot/positioner and the robot controller. The sig-nals are converted in the RDC (A/D conversion).

Robot system Robot system, consisting of robot, positioner,robot controller, KUKA System Software, con-necting cables and KCP.

Safety zone The safety zone is situated outside the danger zone.

Fixture A customer-specific fixture adapted to the rele-vant application is mounted on the positioner.

External axis If the positioner is connected to the robot control-ler, its axes are configured as external axes of the robot.

Term Description




2 Purpose

2 Purpose

2.1 Intended use

Use The intended use of the positioner is the movement and positioning of loadsand workpieces.

The positioner is designed exclusively for the specified applications.

Use for any other or additional purpose is considered impermissible misuse.The manufacturer cannot be held liable for any damage resulting from suchuse. The risk lies entirely with the user.

Operation in accordance with the intended use also involves continuous ob-servance of the operating instructions with particular reference to the mainte-nance specifications.

Impermissible

misuse

Any use or application deviating from the intended use is deemed to be imper-missible misuse; examples of such misuse include:

Transportation of persons and animals

Use as a climbing aid

Operation outside the permissible technical operating parameters

Use in potentially explosive environments

2.2 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

Advanced knowledge of programming external axes

Advanced knowledge of machine data

Knowledge of the robot controller system

Further information is contained in the technical data of the operatingor assembly instructions for the positioner and its options.

The positioner is an integral part of an overall system and may onlybe operated in a CE-compliant system.

For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information aboutthe training program can be found at www.kuka.com or can be ob-tained directly from our subsidiaries.




3 Product description


3.1 Overview

Posiflex KPF5-

V2H2H500

The positioner is controlled by the robot controller as an external axis.

The positioner consists of the following components:

Base frame

Main axes:

Main axis

Swivel axes

Planetary axes

Electrical installations

3.2 Description of the positioner

Overview The positioner has 5 axes which are controlled via the robot controller. A cus-tomer-specific or project-specific fixture is mounted by means of a mechanicalinterface (e.g. locating holes and threaded holes). The system may optionally

have an energy supply system integrated into it (e.g. for compressed air, elec-trical current).

In the following text the axes of the positioner are assigned as an example toaxes 7 ... 11 of the robot controller. In the actual application, A7 ... A11 mightalready be assigned to different system components.

Type Payload

KPF5-V2H2H500 500 kg

Fig. 3-1: KPF5-V2H2H500

1 Planetary axes 3 Main axis

2 Swivel axis





Base frame The base frame is the base of the positioner. It supports the main axis and isbolted to the floor.

Main axis The main axis of the positioner consists of motor, gear unit, bearings and mainbeam. 2 swivel axes are mounted on the main beam.

The main axis may optionally be fitted with working range monitoring.

Swivel axes The swivel axes each consist of a motor and gear unit, on which the planetaryaxes are mounted.

Planetary axes The planetary axes consist of motor, gear unit, counterbearing and flanges;the workpiece fixtures are mounted on the flanges.

Electrical installa-

tions

The electrical installations consist of the cables and connectors, along with therelevant holders, flexible tube and accessories .

The positioner has its own RDC (2nd RDC) located in the junction box on thebase frame.

3.3 Control and integration

Description The drive units of the positioner are operated as external axes of the robotcontroller. The following couplings are possible:

Asynchronous operation. There is no mathematical coupling with the ro-bot.

Mathematical coupling of one or more drive units into the robot kinematicsystem.

Root point calibration is required for the mathematical coupling.

An example of a mathematical coupling is depicted in the following diagram.

Fig. 3-2: Description of Posiflex KPF5-V2H2H500

1 Counterbearing of planetaryaxes

5 Connection of 2nd RDC

2 Swivel axis 6 Connector panel

3 Drive of planetary axes 7 Base frame4 Main beam

Further information about calibration of an external kinematic systemis contained in the Operating and Programming Instructions for Sys-tem Integrators.





With mathematical coupling, the robot constantly follows the movement of thecoupled external axes. The mathematical coupling can simplify the program-ming for complex processes, e.g. arc welding. Using this method, a constantdefined orientation can be maintained during a CP motion, for example.

3.4 Connecting cables

Fig. 3-3: Robot with external axes and extended kinematic system

Fig. 3-4: Robot controller connection

1 Robot controller 5 Control cable A72 Control cable for positioner 6 Motor cable for robot

3 Motor cables for positioner 7 Control cable for robot

4 Junction box on positioner (2nd RDC)

8 Junction box on robot(1st RDC)





The cable lengths are customer-specific.

3.5 Description of the electrical installations

Overview The electrical installations of the positioner consist of the following compo-nents:

Cable set

Junction box, control cables, 2nd RDC Connector panel

Description The cables are protected against damage from external influences (e.g. weldspatter, etc.) by means of flexible tubes. The flexible tubes also ensure that thecables are guided without kinking throughout the entire motion range of the po-sitioner.

The connecting cables are connected via the connector panel and the junctionbox in the base frame.

Cable designation Connector on: Connector typePositioner Robot control-

ler

Motor cable A7 XM7 X9.1 Circular power con-nector, size1.5

6-pole

Motor cable A8 XM8 X9.2 Circular power con-nector, size 1

6-pole


6-pole

Motor cable A10 XM10 X9.4 Circular

power con-nector, size 1


Control cable, 2ndRDC

XA21 X31.2 Signal cou-pling circular connector ateach end

17-pole

Working range moni-

toring

X74 Harting sur-

face-mountedhousing -hood, HAN25





The ground conductor is fastened directly to the base frame.

The motors of the positioner each have 2 connectors for the electrical connec-tion:

Motor cable connector (motor and brake)

Control cable connector (control signals and temperature monitoring)

Cables The following table describes the cables between the motors and the connec-tor panel or the RDC on the base frame.

Fig. 3-5: KPF5-V2H2H500, connection on connector panel and 2nd RDC

1 Junction box, control cables, 2nd RDC

2 Connector panel (connection of motor cables and control cable A7; op-tionally energy supply system)

Fig. 3-6: Motor on positioner (example)

1 Motor 3 Connector for control cable

2 Connector for motor cable

Cable designation Motor connector Connector panel or RDC

Motor cable A7 XM7 XM7.1





Control cable A7 XP7 XP7.1









Cable designation Motor connector Connector panel or RDC




4 Technical data

4 Technical data

4.1 Basic data

Posiflex KPF5-V2H2H500

The weight depends on the customer-specific design of the positioner. The rel-evant information is available from KUKA Roboter GmbH on request.

Ambient temper-

ature

4.2 Axis data

Direction of

rotation

The orientation of a rotational axis is defined on the motor side:

“+” clockwise

“-” counterclockwise

The direction of motion and the arrangement of the individual axes may be not-ed from the following diagram:

Number of axes 5

Sound level < 75 dB (A) outside the working envelope

Electrical protection class IP 67

Operation +5 °C to +40 °C (278 K to 313 K)

Storage and transportation +5 °C to +40 °C (278 K to 313 K)

Start-up +5 °C to +40 °C (278 K to 313 K)

Axis Range of motion, software-limited

Velocity

A7 +/-185° 75°/s

A8 +/-95° 72°/s

A9 +/-190° 132°/s

A10 +/-95° 72°/s

A11 +/-190° 132°/s

Fig. 4-1: Directions of rotation





Working

envelope

The following diagrams show the shape and size of the working envelope. Thepositioners are manufactured with project-specific dimensions according tothe specified dimension ranges.

Fig. 4-2: Direction of rotation of the axes

Fig. 4-3: Working envelope, front view

Fig. 4-4: Working envelope, side view




4 Technical data

The distance between the face plates (dimension F) and the tool radius (di-mension C) depend on the customer-specific design of the positioner.

4.3 Payloads

4.4 Loads acting on the mounting base

Description Additional forces and torques occur as a result of the load and motion duringoperation:

The specified forces and moments already include the payload and the inertiaforce (weight) of the positioner.

Fig. 4-5: Working envelope, top view

Dimensions (mm)

A F + 900 mm

B G + 2C

C 500 … 800 mm

D C + 205 mm

E 2,145 … 2,375 mm

F 1,600 … 2,000 mm

G 1,900 mm + 2CH 1,190 mm

Payload: 500 kg A7 A8/A9 A10/A11

Max. available torque [Nm] 8600 2480 580

Moment of inertia [kgm2] 6700 1500 110

Fv Vertical force

Fh Horizontal force

Mk Tilting moment

Mr Torque about the vertical axis





Max. mounting base data:

4.5 Additional data

Accessories Only accessories authorized by KUKA Roboter GmbH for this positioner maybe used. All items of equipment must possess the appropriate certification anddeclarations of conformity.

Options Application-specific energy supply system:

Air, control/parameter cable, ground, water Signal transmission by bus cable (Profibus)

Insulation of the face plates

Support strips for fixtures

Planetary axis with integrated routing of energy supply system

Working range monitoring

Weld current return cable

Rotary distributor

4.6 Plates and labels

Plates and labels The following plates, labels and signs are attached to the positioner. Theymust not be removed or rendered illegible. Illegible plates, labels and signsmust be replaced.

Fig. 4-6: Loads acting on the mounting base, front view

Fig. 4-7: Loads acting on the mounting base, top view

Fvmax 40500 N

Fhmax 23500 NMkmax 84500 Nm

Mrmax 45500 Nm




4 Technical data

Signs 6 and 7 are also attached to the motor that drives the main axis.

Fig. 4-8: Set of plates, positions




5 Safety

5 Safety

5.1 General

5.1.1 Liability

The device described in this document is either an industrial robot or a com-ponent thereof.

Components of the industrial robot:

Manipulator

Robot controller

Teach pendant

Connecting cables

External axes (optional)

e.g. linear unit, turn-tilt table, positioner

Software Options, accessories

The industrial robot is built using state-of-the-art technology and in accor-dance with the recognized safety rules. Nevertheless, misuse of the industrialrobot may constitute a risk to life and limb or cause damage to the industrialrobot and to other material property.

The industrial robot may only be used in perfect technical condition in accor-dance with its intended use and only by safety-conscious persons who are ful-ly aware of the risks involved in its operation. Use of the industrial robot issubject to compliance with this document and with the declaration of incorpo-ration supplied together with the industrial robot. Any functional disorders af-

fecting the safety of the industrial robot must be rectified immediately.

Safety infor-

mation

Safety information cannot be held against KUKA Roboter GmbH. Even if allsafety instructions are followed, this is not a guarantee that the industrial robotwill not cause personal injuries or material damage.

No modifications may be carried out to the industrial robot without the autho-rization of KUKA Roboter GmbH. Additional components (tools, software,etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus-trial robot. The user is liable for any damage these components may cause tothe industrial robot or to other material property.

In addition to the Safety chapter, this document contains further safety instruc-tions. These must also be observed.

This “Safety” chapter refers to a mechanical component of an indus-trial robot.

If the mechanical component is used together with a KUKA robotcontroller, the “Safety” chapter of the operating instructions or assemblyinstructions of the robot controller must be used!

This contains all the information provided in this “Safety” chapter. It alsocontains additional safety information relating to the robot controller which must be observed.

Where this “Safety” chapter uses the term “industrial robot”, this also re-fers to the individual mechanical component if applicable.





5.1.2 Intended use of the industrial robot

The industrial robot is intended exclusively for the use designated in the “Pur-pose” chapter of the operating instructions or assembly instructions.

Using the industrial robot for any other or additional purpose is considered im-permissible misuse. The manufacturer cannot be held liable for any damageresulting from such use. The risk lies entirely with the user.

Operating the industrial robot and its options within the limits of its intendeduse also involves observance of the operating and assembly instructions for the individual components, with particular reference to the maintenance spec-ifications.

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

Operation without additional safeguards

Outdoor operation

5.1.3 EC declaration of conformity and declaration of incorporation

This industrial robot constitutes partly completed machinery as defined by theEC Machinery Directive. The industrial robot may only be put into operation if

the following preconditions are met: The industrial robot is integrated into a complete system.

Or: The industrial robot, together with other machinery, constitutes a com-plete system.

Or: All safety functions and safeguards required for operation in the com-plete machine as defined by the EC Machinery Directive have been addedto the industrial robot.

The complete system complies with the EC Machinery Directive. This hasbeen confirmed by means of an assessment of conformity.

Declaration of

conformity

The system integrator must issue a declaration of conformity for the complete

system in accordance with the Machinery Directive. The declaration of confor-mity forms the basis for the CE mark for the system. The industrial robot mustbe operated in accordance with the applicable national laws, regulations andstandards.

The robot controller is CE certified under the EMC Directive and the Low Volt-age Directive.

Declaration of

incorporation

The industrial robot as partly completed machinery is supplied with a declara-tion of incorporation in accordance with Annex II B of the EC Machinery Direc-tive 2006/42/EC. The assembly instructions and a list of essentialrequirements complied with in accordance with Annex I are integral parts of this declaration of incorporation.

The declaration of incorporation declares that the start-up of the partly com-pleted machinery remains impermissible until the partly completed machineryhas been incorporated into machinery, or has been assembled with other parts

Further information is contained in the “Purpose” chapter of the oper-ating instructions or assembly instructions of the industrial robot.




5 Safety

to form machinery, and this machinery complies with the terms of the EC Ma-chinery Directive, and the EC declaration of conformity is present in accor-dance with Annex II A.

The declaration of incorporation, together with its annexes, remains with thesystem integrator as an integral part of the technical documentation of thecomplete machinery.

5.1.4 Terms used

5.2 Personnel

The following persons or groups of persons are defined for the industrial robot:

User

Personnel

Term Description

Axis range Range of each axis, in degrees or millimeters, within which it may move.The axis range must be defined for each axis.

Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.

Workspace The manipulator is allowed to move within its workspace. The work-space is derived from the individual axis ranges.

Operator (User)

The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot.

Danger zone The danger zone consists of the workspace and the stopping distances.

KCP The KCP (KUKA Control Panel) teach pendant has all the operator con-trol and display functions required for operating and programming theindustrial robot.

Manipulator The robot arm and the associated electrical installations

Safety zone The safety zone is situated outside the danger zone.

Stop category 0 The drives are deactivated immediately and the brakes are applied. Themanipulator and any external axes (optional) perform path-orientedbraking.

Note: This stop category is called STOP 0 in this document.Stop category 1 The manipulator and any external axes (optional) perform path-main-

taining braking. The drives are deactivated after 1 s and the brakes areapplied.

Note: This stop category is called STOP 1 in this document.

Stop category 2 The drives are not deactivated and the brakes are not applied. Themanipulator and any external axes (optional) are braked with a normalbraking ramp.

Note: This stop category is called STOP 2 in this document.

System integrator (plant integrator)

System integrators are people who safely integrate the industrial robotinto a complete system and commission it.

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

External axis Motion axis which is not part of the manipulator but which is controlledusing the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.

All persons working with the industrial robot must have read and un-derstood the industrial robot documentation, including the safetychapter.





User The user must observe the labor laws and regulations. This includes e.g.:

The user must comply with his monitoring obligations.

The user must carry out instructions at defined intervals.

Personnel Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may ex-ist. Instruction must be carried out regularly. Instruction is also required after

particular incidents or technical modifications.

Personnel includes:

System integrator

Operators, subdivided into:

Start-up, maintenance and service personnel

Operating personnel

Cleaning personnel

System integrator The industrial robot is safely integrated into a complete system by the systemintegrator.

The system integrator is responsible for the following tasks:

Installing the industrial robot

Connecting the industrial robot

Performing risk assessment

Implementing the required safety functions and safeguards

Issuing the declaration of conformity

Attaching the CE mark

Creating the operating instructions for the complete system

Operator The operator must meet the following preconditions:

The operator must be trained for the work to be carried out.

Work on the industrial robot must only be carried out by qualified person-nel. These are people who, due to their specialist training, knowledge andexperience, and their familiarization with the relevant standards, are ableto assess the work to be carried out and detect any potential hazards.

Example The tasks can be distributed as shown in the following table.

Installation, exchange, adjustment, operation, maintenance and re-pair must be performed only as specified in the operating or assembly

instructions for the relevant component of the industrial robot and onlyby personnel specially trained for this purpose.

Tasks Operator Programmer System inte-grator

Switch robot controller on/off

x x x

Start program x x x

Select program x x x

Select operating mode x x x

Calibration(tool, base)

x x

Master the manipulator x x

Configuration x xProgramming x x

Start-up x




5 Safety

5.3 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspacemust be safeguarded using appropriate safeguards.

The safeguards (e.g. safety gate) must be situated inside the safety zone. Inthe case of a stop, the manipulator and external axes (optional) are braked

and come to a stop within the danger zone.The danger zone consists of the workspace and the stopping distances of themanipulator and external axes (optional). It must be safeguarded by means of physical safeguards to prevent danger to persons or the risk of material dam-age.

5.4 Overview of protective equipment

The protective equipment of the mechanical component may include:

Mechanical end stops

Mechanical axis range limitation (optional)

Axis range monitoring (optional)

Maintenance x

Repair x

Decommissioning x

Transportation x

Work on the electrical and mechanical equipment of the industrial ro-bot may only be carried out by specially trained personnel.

Tasks Operator Programmer System inte-grator

Fig. 5-1: Example of axis range A1

1 Workspace 3 Stopping distance

2 Manipulator 4 Safety zone





Release device (optional)

Labeling of danger areas

Not all equipment is relevant for every mechanical component.

5.4.1 Mechanical end stops

The axis ranges of main axes A1 to A3 and wrist axis A5 of the manipulator are limited by means of mechanical end stops with buffers.

Additional mechanical end stops can be installed on the external axes.

5.4.2 Mechanical axis range limitation (optional)

Some manipulators can be fitted with mechanical axis range limitation in axes A1 to A3. The adjustable axis range limitation systems restrict the workingrange to the required minimum. This increases personal safety and protectionof the system.

In the case of manipulators that are not designed to be fitted with mechanicalaxis range limitation, the workspace must be laid out in such a way that thereis no danger to persons or material property, even in the absence of mechan-ical axis range limitation.

If this is not possible, the workspace must be limited by means of photoelectricbarriers, photoelectric curtains or obstacles on the system side. There must beno shearing or crushing hazards at the loading and transfer areas.

5.4.3 Axis range monitoring (optional)

Some manipulators can be fitted with dual-channel axis range monitoring sys-tems in main axes A1 to A3. The positioner axes may be fitted with additionalaxis range monitoring systems. The safety zone for an axis can be adjustedand monitored using an axis range monitoring system. This increases person-al safety and protection of the system.

5.4.4 Release device (optional)

Description The release device can be used to move the manipulator manually after an ac-cident or malfunction. The release device can be used for the main axis drivemotors and, depending on the robot variant, also for the wrist axis drive mo-

If the manipulator or an external axis hits an obstructionor a buffer on the mechanical end stop or axis range lim-

itation, this can result in material damage to the industrial robot. KUKA Ro-boter GmbH must be consulted before the industrial robot is put back intooperation. (>>> 9 "KUKA Service" Page 47)The affected buffer must be replaced with a new one before operation of theindustrial robot is resumed. If a manipulator (or external axis) collides with abuffer at more than 250 mm/s, the manipulator (or external axis) must be ex-

changed or recommissioning must be carried out by KUKA Roboter GmbH.

This option is not available for all robot models. Information on spe-cific robot models can be obtained from KUKA Roboter GmbH.

This option is not available for all robot models. Information on spe-cific robot models can be obtained from KUKA Roboter GmbH.




5 Safety

tors. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people).

Procedure 1. Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized persons from switching it on again.

2. Remove the protective cap from the motor.

3. Push the release device onto the corresponding motor and move the axisin the desired direction.

The directions are indicated with arrows on the motors. It is necessary toovercome the resistance of the mechanical motor brake and any other loads acting on the axis.

5.4.5 Labeling on the industrial robot

All plates, labels, symbols and marks constitute safety-relevant parts of the in-dustrial robot. They must not be modified or removed.

Labeling on the industrial robot consists of:

Identification plates

Warning labels

Safety symbols Designation labels

Cable markings

Rating plates

5.5 Safety measures

5.5.1 General safety measures

The industrial robot may only be used in perfect technical condition in accor-dance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property.

It is important to be prepared for possible movements of the industrial roboteven after the robot controller has been switched off and locked. Incorrect in-stallation (e.g. overload) or mechanical defects (e.g. brake defect) can causethe manipulator or external axes to sag. If work is to be carried out on aswitched-off industrial robot, the manipulator and external axes must first bemoved into a position in which they are unable to move on their own, whether

the payload is mounted or not. If this is not possible, the manipulator and ex-ternal axes must be secured by appropriate means.

The motors reach temperatures during operation whichcan cause burns to the skin. Contact must be avoided.

Appropriate safety precautions must be taken, e.g. protective gloves must beworn.

Moving an axis with the release device can damage themotor brake. This can result in personal injury and mate-

rial damage. After using the release device, the affected motor must be ex-changed.

Further information is contained in the technical data of the operatinginstructions or assembly instructions of the components of the indus-trial robot.





KCP The user must ensure that the industrial robot is only operated with the KCPby authorized persons.

If more than one KCP is used in the overall system, it must be ensured thateach KCP is unambiguously assigned to the corresponding industrial robot.

They must not be interchanged.

External

keyboard,

external mouse

An external keyboard and/or external mouse may only be used if the followingconditions are met:

Start-up or maintenance work is being carried out.

The drives are switched off.

There are no persons in the danger zone.

The KCP must not be used as long as an external keyboard and/or externalmouse are connected.

The external keyboard and/or external mouse must be removed as soon asthe start-up or maintenance work is completed or the KCP is connected.

Faults The following tasks must be carried out in the case of faults in the industrialrobot:

Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized persons from switching it on again.

Indicate the fault by means of a label with a corresponding warning (tag-out).

Keep a record of the faults.

Eliminate the fault and carry out a function test.

Modifications After modifications to the industrial robot, checks must be carried out to ensurethe required safety level. The valid national or regional work safety regulationsmust be observed for this check. The correct functioning of all safety circuitsmust also be tested.

New or modified programs must always be tested first in Manual Reduced Ve-locity mode (T1).

In the absence of operational safety functions and safe-guards, the industrial robot can cause personal injury or

material damage. If safety functions or safeguards are dismantled or deacti-vated, the industrial robot may not be operated.

Standing underneath the robot arm can cause death or serious physical injuries. For this reason, standing un-

derneath the robot arm is prohibited!

The motors reach temperatures during operation whichcan cause burns to the skin. Contact must be avoided.

Appropriate safety precautions must be taken, e.g. protective gloves must beworn.

The operator must ensure that decoupled KCPs are im-mediately removed from the system and stored out of

sight and reach of personnel working on the industrial robot. This serves toprevent operational and non-operational EMERGENCY STOP facilities frombecoming interchanged.Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.




5 Safety

After modifications to the industrial robot, existing programs must always betested first in Manual Reduced Velocity mode (T1). This applies to all compo-nents of the industrial robot and includes modifications to the software andconfiguration settings.

5.5.2 Transportation

Manipulator The prescribed transport position of the manipulator must be observed. Trans-portation must be carried out in accordance with the operating instructions or assembly instructions of the manipulator.

Robot controller The robot controller must be transported and installed in an upright position. Avoid vibrations and impacts during transportation in order to prevent damageto the robot controller.

Transportation must be carried out in accordance with the operating instruc-tions or assembly instructions of the robot controller.

External axis

(optional)

The prescribed transport position of the external axis (e.g. KUKA linear unit,turn-tilt table, etc.) must be observed. Transportation must be carried out in ac-

cordance with the operating instructions or assembly instructions of the exter-nal axis.

5.5.3 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be car-ried out to ensure that the systems and devices are complete and operational,that they can be operated safely and that any damage is detected.

The valid national or regional work safety regulations must be observed for thischeck. The correct functioning of all safety circuits must also be tested.

Function test The following tests must be carried out before start-up and recommissioning:

It must be ensured that: The industrial robot is correctly installed and fastened in accordance with

the specifications in the documentation.

The passwords for logging onto the KUKA System Software as “Ex-pert” and “Administrator” must be changed before start-up and mustonly be communicated to authorized personnel.

The robot controller is preconfigured for the specific in-dustrial robot. If cables are interchanged, the manipula-

tor and the external axes (optional) may receive incorrect data and can thuscause personal injury or material damage. If a system consists of more thanone manipulator, always connect the connecting cables to the manipulatorsand their corresponding robot controllers.

If additional components (e.g. cables), which are not part of the scope

of supply of KUKA Roboter GmbH, are integrated into the industrialrobot, the user is responsible for ensuring that these components do

not adversely affect or disable safety functions.

If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensa-

tion can form, which may cause damage to the electrical components. Do notput the robot controller into operation until the internal temperature of thecabinet has adjusted to the ambient temperature.





There are no foreign bodies or loose parts on the industrial robot.

All required safety equipment is correctly installed and operational.

The power supply ratings of the industrial robot correspond to the localsupply voltage and mains type.

The ground conductor and the equipotential bonding cable are sufficientlyrated and correctly connected.

The connecting cables are correctly connected and the connectors arelocked.

Machine data It must be ensured that the rating plate on the robot controller has the samemachine data as those entered in the declaration of incorporation. The ma-chine data on the rating plate of the manipulator and the external axes (option-al) must be entered during start-up.

5.5.4 Manual mode

Manual mode is the mode for setup work. Setup work is all the tasks that haveto be carried out on the industrial robot to enable automatic operation. Setupwork includes:

Jog mode

Teach

Programming

Program verification

The following must be taken into consideration in manual mode: If the drives are not required, they must be switched off to prevent the ma-

nipulator or the external axes (optional) from being moved unintentionally.

New or modified programs must always be tested first in Manual ReducedVelocity mode (T1).

The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence.

Workpieces, tooling and other objects must not become jammed as a re-sult of the industrial robot motion, nor must they lead to short-circuits or beliable to fall off.

All setup work must be carried out, where possible, from outside the safe-

guarded area.If the setup work has to be carried out inside the safeguarded area, the follow-ing must be taken into consideration:

In Manual Reduced Velocity mode (T1):

If it can be avoided, there must be no other persons inside the safeguard-ed area.

If it is necessary for there to be several persons inside the safeguarded ar-ea, the following must be observed:

Each person must have an enabling device.

All persons must have an unimpeded view of the industrial robot.

Eye-contact between all persons must be possible at all times. The operator must be so positioned that he can see into the danger area

and get out of harm’s way.

The industrial robot must not be moved if incorrect ma-chine data are loaded. Death, severe physical injuries or

considerable damage to property may otherwise result. The correct machinedata must be loaded.




5 Safety

In Manual High Velocity mode (T2):

This mode may only be used if the application requires a test at a velocityhigher than Manual Reduced Velocity.

Teaching and programming are not permissible in this operating mode.

Before commencing the test, the operator must ensure that the enablingdevices are operational.

The operator must be positioned outside the danger zone. There must be no other persons inside the safeguarded area. It is the re-

sponsibility of the operator to ensure this.

5.5.5 Automatic mode

Automatic mode is only permissible in compliance with the following safetymeasures:

All safety equipment and safeguards are present and operational.

There are no persons in the system.

The defined working procedures are adhered to.

If the manipulator or an external axis (optional) comes to a standstill for no ap-parent reason, the danger zone must not be entered until an EMERGENCYSTOP has been triggered.

5.5.6 Maintenance and repair

After maintenance and repair work, checks must be carried out to ensure therequired safety level. The valid national or regional work safety regulationsmust be observed for this check. The correct functioning of all safety circuitsmust also be tested.

The purpose of maintenance and repair work is to ensure that the system iskept operational or, in the event of a fault, to return the system to an operation-al state. Repair work includes troubleshooting in addition to the actual repair itself.

The following safety measures must be carried out when working on the indus-trial robot:

Carry out work outside the danger zone. If work inside the danger zone isnecessary, the user must define additional safety measures to ensure thesafe protection of personnel.

Switch off the industrial robot and secure it (e.g. with a padlock) to preventit from being switched on again. If it is necessary to carry out work with the

robot controller switched on, the user must define additional safety mea-sures to ensure the safe protection of personnel.

If it is necessary to carry out work with the robot controller switched on, thismay only be done in operating mode T1.

Label the system with a sign indicating that work is in progress. This signmust remain in place, even during temporary interruptions to the work.

The EMERGENCY STOP systems must remain active. If safety functionsor safeguards are deactivated during maintenance or repair work, theymust be reactivated immediately after the work is completed.





Faulty components must be replaced using new components with the samearticle numbers or equivalent components approved by KUKA Roboter GmbHfor this purpose.

Cleaning and preventive maintenance work is to be carried out in accordancewith the operating instructions.

Robot controller Even when the robot controller is switched off, parts connected to peripheral

devices may still carry voltage. The external power sources must therefore beswitched off if work is to be carried out on the robot controller.

The ESD regulations must be adhered to when working on components in therobot controller.

Voltages in excess of 50 V (up to 600 V) can be present in various componentsfor several minutes after the robot controller has been switched off! To preventlife-threatening injuries, no work may be carried out on the industrial robot inthis time.

Water and dust must be prevented from entering the robot controller.

Counterbal-

ancing system

Some robot variants are equipped with a hydropneumatic, spring or gas cylin-

der counterbalancing system.The hydropneumatic and gas cylinder counterbalancing systems are pressureequipment and, as such, are subject to obligatory equipment monitoring. De-pending on the robot variant, the counterbalancing systems correspond to cat-egory 0, II or III, fluid group 2, of the Pressure Equipment Directive.

The user must comply with the applicable national laws, regulations and stan-dards pertaining to pressure equipment.

Inspection intervals in Germany in accordance with Industrial Safety Order,Sections 14 and 15. Inspection by the user before commissioning at the instal-lation site.

The following safety measures must be carried out when working on the coun-terbalancing system:

The manipulator assemblies supported by the counterbalancing systemsmust be secured.

Work on the counterbalancing systems must only be carried out by quali-fied personnel.

Hazardous

substances

The following safety measures must be carried out when handling hazardoussubstances:

Avoid prolonged and repeated intensive contact with the skin.

Avoid breathing in oil spray or vapors.

Clean skin and apply skin cream.

Before work is commenced on live parts of the robot sys-tem, the main switch must be turned off and secured

against being switched on again by unauthorized personnel. The incomingpower cable must be deenergized. The robot controller and mains supplylead must then be checked to ensure that it is deenergized.If the KR C4 or VKR C4 robot controller is used:It is not sufficient, before commencing work on live parts, to execute an

EMERGENCY STOP or a safety stop, or to switch off the drives, as this doesnot disconnect the robot system from the mains power supply in the case of the drives of the new generation. Parts remain energized. Death or severephysical injuries may result.




5 Safety

5.5.7 Decommissioning, storage and disposal

The industrial robot must be decommissioned, stored and disposed of in ac-cordance with the applicable national laws, regulations and standards.

5.6 Applied norms and regulations

To ensure safe use of our products, we recommend that our custom-ers regularly request up-to-date safety data sheets from the manufac-turers of hazardous substances.

Name Definition Edition

2006/42/EC Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amendingDirective 95/16/EC (recast)

2006

2004/108/EC EMC Directive:Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagneticcompatibility and repealing Directive 89/336/EEC

2004

97/23/EC Pressure Equipment Directive:

Directive 97/23/EC of the European Parliament and of theCouncil of 29 May 1997 on the approximation of the lawsof the Member States concerning pressure equipment

(Only applicable for robots with hydropneumatic counter-balancing system.)

1997

EN ISO 13850 Safety of machinery:

Emergency stop - Principles for design

2008

EN ISO 13849-1 Safety of machinery:

Safety-related parts of control systems - Part 1: Generalprinciples of design

2008


Safety-related parts of control systems - Part 2: Validation

2008


Basic concepts, general principles for design - Part 1:

Basic terminology, methodology

2003


Basic concepts, general principles for design - Part 2:Technical principles

2003

EN ISO 10218-1 Industrial robots:

Safety

2008

EN 614-1 Safety of machinery:

Ergonomic design principles - Part 1: Terms and generalprinciples

2006

EN 61000-6-2 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial envi-ronments

2005





EN 61000-6-4 Electromagnetic compatibility (EMC):

Part 6-4: Generic standards; Emission standard for indus-trial environments

2007

EN 60204-1 Safety of machinery:

Electrical equipment of machines - Part 1: Generalrequirements

2006

Name Definition Edition




6 Planning

6 Planning

6.1 KPF5-V2H2H500 mounting base with centering

Description This section describes the mounting base of the positioner KPF5-V2H2H. Thepositioner is installed and secured on the floor, directly onto the concrete foun-dation. The surface of the foundation must be level and smooth. The minimumdimensions must be observed.

The mounting base with centering consists of:

Bedplates

Resin-bonded anchors

Fasteners

Grade of concretefor foundations

When producing foundations from concrete, observe the load-bearing capac-ity of the ground and the country-specific construction regulations. The con-crete must have no cracks and fulfill the following norms for quality:

B25 according to DIN 1045:1988

C20/25 according to DIN EN 206-1:2001/DIN 1045-2:2001

Dimensioned

drawing

The following illustrations provide all the necessary information on the mount-ing base, together with the required foundation data.

To ensure full functionality, the positioner must be fastened to abooster frame.If the positioner is installed directly on the floor, A8 and A9 cannot be

rotated fully.

Fig. 6-1: KPF5-V2H2H500 mounting base with centering

1 Hexagon bolt 3 Resin-bonded anchor

2 Bedplate 4 Pin for centering





To ensure that the anchor forces are safely transmitted to the foundation, ob-

serve the dimensions for concrete foundations specified in the following illus-tration.

6.2 KPF5-V2H2H500 machine frame mounting assembly

Description The machine frame mounting assembly with centering is used when the posi-

tioner is fastened on a steel structure, a booster frame (pedestal) or a KUKAlinear unit. It must be ensured that the substructure is able to withstand safelythe forces occurring during operation (foundation loads). The following dia-

Fig. 6-2: KPF5-V2H2H500 mounting base with centering, dimensioneddrawing

1 Pin for centering 3 Bedplate

2 Hexagon bolts

Fig. 6-3: KPF5-V2H2H500 cross-section of foundation

1 Bedplate 3 Concrete foundation

2 Resin-bonded anchor




6 Planning

gram contains all the necessary information that must be observed when pre-paring the mounting surface.

For further data concerning the machine frame mounting assembly, see(>>> Fig. 6-4 ).

The machine frame mounting assembly consists of:

Pin with fasteners

Sword pin with fasteners Hexagon bolts with conical spring washers

6.3 Dimensions of face plates

The face plates have the dimensions specified in the following drawings for allpositioner variants.

Fig. 6-4: Installing the KPF5-V2H2H500 machine frame mounting assem-bly

1 Allen screw, 8x 3 Pin

2 Sword pin 4 Mounting surface





Fig. 6-5: Hole pattern for face plate on motor side

1 Mounting borehole for support strip




6 Planning

Fig. 6-6: Hole pattern for face plate, counterbearing

1 Mounting borehole for support strip




7 Transportation

7 Transportation

7.1 Transportation

Description The positioner must be dismantled to the following components each time it istransported:

Before the components are lifted, it must be ensured that they are free fromobstructions. Remove all transport safeguards, such as nails and screws, inadvance. First remove any rust or glue on contact surfaces.

Transport dimen-

sions

The position of the center of gravity and the weight vary according to the spe-cific configuration. The specified dimensions refer to the positioner withoutequipment.

Fig. 7-1: Transporting the components

1 Swivel axis 2 Main beam

Use of unsuitable handling equipment may result in dam-age to the positioner. Only use handling equipment with

a sufficient load-bearing capacity. The positioner may only be transported in

the manner specified here.

The components of the positioner may tip during trans-portation. Risk of personal injury and damage to proper-

ty. The components must be secured to prevent them from tipping.

Fig. 7-2: Transport dimensions, front view





The distance between the face plates (dimension F in the following figure) de-pends on the customer-specific design of the positioner.

The dimension of the planetary axis drive (dimension J in the following figure)depends on the customer-specific tool radius.

Transportation by

fork lift truck

The main beam can be transported by fork lift truck.

For transport by fork lift truck, two fork slots are provided in the main beam.The main beam can be picked up by the fork lift truck from the front and rear.The main beam must not be damaged when inserting the forks into the forkslots. The fork lift truck must have a minimum payload capacity of 3,500 kg andan adequate fork length.

Fig. 7-3: Transport dimensions, top view

Dimensions (mm)

F 1,600 … 2,000 mm

J 1,080 … 1,380 mm

Avoid excessive loading of the fork slots through undueinward or outward movement of hydraulically adjustable

forks of the fork lift truck.




7 Transportation

Transportation

using lifting

tackle

The swivel axes are transported using lifting tackle (>>> Fig. 7-5 ). The liftingtackle is looped around the tubes of the planetary axes as a sling. All ropesmust be long enough and must be routed in such a way that the swivel axesare not damaged. Pay attention to the center of gravity of the swivel axis whenlifting.

The main beam can also be transported using lifting tackle (>>> Fig. 7-6 ).The lifting tackle is attached at 2 points to M24 eyebolts. All ropes must be longenough and must be routed in such a way that the main beam is not damaged.

Fig. 7-4: Transporting the main beam by fork lift truck

Fig. 7-5: Transporting the swivel axes

1 Crane 3 Swivel axis

2 Lifting tackle





Fig. 7-6: Transporting the main beam with lifting tackle

1 Lifting tackle 3 Main beam

2 Eyebolt 4 Crane




8 Appendix

8 Appendix

8.1 Tightening torque

Tightening torque The following tightening torques are valid for screws and nuts where no other specifications are given.

Tighten M5 domed cap nuts with a torque of 4.2 Nm.

Strength class

Screw size 8.8 10.9 12.9

M3 1.2 Nm 1.6 Nm 2.0 Nm

M4 2.8 Nm 3.7 Nm 4.4 Nm

M5 5.6 Nm 7.5 Nm 9.0 Nm

M6 9.5 Nm 12.5 Nm 15.0 Nm

M8 23.0 Nm 31.0 Nm 36.0 Nm

M10 45.0 Nm 60.0 Nm 70.0 Nm

M12 78.0 Nm 104.0 Nm 125.0 Nm

M14 125.0 Nm 165.0 Nm 195.0 Nm

M16 195.0 Nm 250.0 Nm 305.0 Nm

M20 370.0 Nm 500.0 Nm 600.0 Nm

M24 640.0 Nm 860.0 Nm 1030.0 Nm

M30 1330.0 Nm 1700.0 Nm 2000.0 Nm




9 KUKA Service

9 KUKA Service

9.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation andprovides assistance with troubleshooting. For further assistance, please con-

tact your local KUKA subsidiary.Information The following information is required for processing a support request:

Model and serial number of the robot

Model and serial number of the controller

Model and serial number of the linear unit (if applicable)

Version of the KUKA System Software

Optional software or modifications

Archive of the software

For KUKA System Software V8: instead of a conventional archive, gener-ate the special data package for fault analysis (via KrcDiag).

Application used

Any external axes used

Description of the problem, duration and frequency of the fault

9.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20Parque Industrial

2400 San Francisco (CBA)

Argentina

Tel. +54 3564 421033

Fax +54 3564 428877

[email protected]

Australia Headland Machinery Pty. Ltd.

Victoria (Head Office & Showroom)

95 Highbury Road

Burwood

Victoria 31 25

Australia

Tel. +61 3 9244-3500

Fax +61 3 9244-3501

[email protected]

www.headland.com.au





Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031

3530 Houthalen

Belgium

Tel. +32 11 516160

Fax +32 11 526794

[email protected]

Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80

Parque Novo Mundo

Jd. Guançã

CEP 02151 900 São Paulo

SP Brazil

Tel. +55 11 69844900

Fax +55 11 62017883

[email protected]

Chile Robotec S.A. (Agency)

Santiago de Chile

Chile

Tel. +56 2 331-5951

Fax +56 2 331-5952

[email protected]

www.robotec.cl

China KUKA Automation Equipment (Shanghai) Co., Ltd.Songjiang Industrial Zone

No. 388 Minshen Road

201612 Shanghai

China

Tel. +86 21 6787-1808

Fax +86 21 6787-1805

[email protected]

www.kuka.cn

Germany KUKA Roboter GmbHZugspitzstr. 140

86165 Augsburg

Germany

Tel. +49 821 797-4000

Fax +49 821 797-1616

[email protected]

www.kuka-roboter.de




9 KUKA Service

France KUKA Automatisme + Robotique SAS

Techvallée

6, Avenue du Parc

91140 Villebon S/Yvette

France

Tel. +33 1 6931660-0

Fax +33 1 [email protected]

www.kuka.fr

India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,

Level 12, Building No. - 9B

DLF Cyber City Phase III

122 002 Gurgaon

Haryana

India

Tel. +91 124 4635774Fax +91 124 4635773

[email protected]

www.kuka.in

Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6

10098 Rivoli (TO)

Italy

Tel. +39 011 959-5013


www.kuka.it

Japan KUKA Robotics Japan K.K.

Daiba Garden City Building 1F

2-3-5 Daiba, Minato-ku

Tokyo

135-0091

Japan

Tel. +81 3 6380-7311Fax +81 3 6380-7312

[email protected]

Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark

1271-11 Sa 3-dong, Sangnok-gu

Ansan City, Gyeonggi Do

426-901

Korea

Tel. +82 31 501-1451






Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office

No. 24, Jalan TPP 1/10

Taman Industri Puchong

47100 Puchong

Selangor

MalaysiaTel. +60 3 8061-0613 or -0614

Fax +60 3 8061-7386

[email protected]

Mexico KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5

Colonia Pensil Sur

C.P. 11490 Mexico D.F.

Mexico

Tel. +52 55 5203-8407


Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9

2821 Gjövik

Norway

Tel. +47 61 133422

Fax +47 61 186200

[email protected]

Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich

Regensburger Strasse 9/1

4020 Linz

Austria

Tel. +43 732 784752

Fax +43 732 793880

[email protected]

www.kuka-roboter.at

Poland KUKA Roboter Austria GmbH

Spółka z ograniczoną odpowiedzialnością

Oddział w Polsce

Ul. Porcelanowa 10

40-246 Katowice

Poland

Tel. +48 327 30 32 13 or -14

Fax +48 327 30 32 26

[email protected]




9 KUKA Service

Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50

Armazém 04

2910 011 Setúbal

Portugal

Tel. +351 265 729780


Russia OOO KUKA Robotics Rus

Webnaja ul. 8A

107143 Moskau

Russia

Tel. +7 495 781-31-20

Fax +7 495 781-31-19

kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15

421 30 Västra Frölunda

Sweden

Tel. +46 31 7266-200

Fax +46 31 7266-201

[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9

5432 Neuenhof Switzerland

Tel. +41 44 74490-90

Fax +41 44 74490-91

[email protected]

www.kuka-roboter.ch

Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial

Torrent de la Pastera

Carrer del Bages s/n08800 Vilanova i la Geltrú (Barcelona)

Spain

Tel. +34 93 8142-353

Fax +34 93 8142-950

[email protected]

www.kuka-e.com





South Africa Jendamark Automation LTD (Agency)

76a York Road

North End

6000 Port Elizabeth

South Africa

Tel. +27 41 391 4700

Fax +27 41 373 3869www.jendamark.co.za

Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road

Jungli City, Taoyuan County 320

Taiwan, R. O. C.

Tel. +886 3 4331988

Fax +886 3 4331948

[email protected]

www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office

c/o Maccall System Co. Ltd.

49/9-10 Soi Kingkaew 30 Kingkaew Road

Tt. Rachatheva, A. Bangpli

Samutprakarn

10540 Thailand

Tel. +66 2 7502737

Fax +66 2 6612355

[email protected]

Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei

Sezemická 2757/2

193 00 Praha

Horní Počernice

Czech Republic

Tel. +420 22 62 12 27 2

Fax +420 22 62 12 27 [email protected]

Hungary KUKA Robotics Hungaria Kft.

Fö út 140

2335 Taksony

Hungary

Tel. +36 24 501609

Fax +36 24 477031

[email protected]




9 KUKA Service

USA KUKA Robotics Corp.

22500 Key Drive

Clinton Township

48036

Michigan

USA

Tel. +1 866 8735852Fax +1 586 5692087

[email protected]

www.kukarobotics.com

UK KUKA Automation + Robotics

Hereward Rise

Halesowen

B62 8AN

UK

Tel. +44 121 585-0800





Index

Index

Numbers2004/108/EC 332006/42/EC 3389/336/EEC 3395/16/EC 33

97/23/EC 33

A

Accessories 18, 21 Ambient temperature 15 Appendix 45 Applied norms and regulations 33 Automatic mode 31 Axis data 15 Axis range 5, 23 Axis range limitation 26 Axis range monitoring 26

Axis velocity 15

Bbase frame 10Basic data 15Brake defect 27Braking distance 5, 23

CCE mark 5, 22Center of gravity 41Cleaning work 32Components 9

Connecting cables 11, 21Connector panel 10Counterbalancing system 32

D

Danger zone 5, 23Declaration of conformity 22Declaration of incorporation 21, 22Decommissioning 33Description, positioner 9Dimensions, transport 41Disposal 33

Drive unit 5

EEC declaration of conformity 22Electrical installations 10, 12Electrical protection class 15EMC Directive 22, 33EN 60204-1 34EN 61000-6-2 33EN 61000-6-4 34EN 614-1 33EN ISO 10218-1 33EN ISO 12100-1 33EN ISO 12100-2 33EN ISO 13849-1 33EN ISO 13849-2 33

EN ISO 13850 33Energy supply system 9External axes 6, 21, 23

F

Face plates 37Faults 28Flexible tube 12Function test 29

G

General safety measures 27

H

Handling equipment 41Hazardous substances 32

IIndustrial robot 21Intended use 22Introduction 5

KKCP 5, 23, 28Keyboard, external 28KPF5-V2H2H500 machine frame mounting as-sembly 36KUKA Customer Support 47

L

Labeling 27Liability 21Linear unit 21Loads acting on the mounting base 17Low Voltage Directive 22

M

Machine data 30Machinery Directive 22, 33Main beam 10Maintenance 31Manipulator 6, 21, 23, 25

Manual mode 30Mechanical axis range limitation 26Mechanical end stops 26Motor of planetary axes 10Mounting base, centering 35Mouse, external 28

OOperator 23, 24Options 21Overload 27

P

Personnel 23Pin 37Planetary axis 10





Plant integrator 23Positioner 6, 21Positioning system 6Pressure Equipment Directive 32, 33Preventive maintenance work 32Product description 9Protective equipment, overview 25

Purpose 7

RRange of motion 15RDC 6, 10Reaction distance 23Recommissioning 29Release device 5, 26Repair 31Robot controller 21Robot system 6

S

Safety 21Safety instructions 5Safety zone 6, 23, 25Safety, general 21Service, KUKA Roboter 47Software 21Start-up 29STOP 0 23STOP 1 23STOP 2 23Stop category 0 23Stop category 1 23

Stop category 2 23Stopping distance 23, 25Storage 33Support request 47Swivel axis 10Sword pin 37System integrator 22, 23, 24

T

T1 23T2 23Teach pendant 21Technical data 15Terms used 5Terms used, safety 23Terms, used 5Tightening torque 45Training 7Transport position 29Transportation 29, 41Turn-tilt table 21

UUse, contrary to intended use 21Use, improper 21

Use, intended 7User 23, 24

WWarnings 5Working envelope 16Working range limitation 26Workspace 5, 23, 25

42e85c7e-7c26-4d85-9dee-b4fffe8ddc15_Spez_KPF5_V2H2H500_en

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