KUKA KR 1000 1300 titan PA; KR 1000 L950 titan PA With F Variants Assembly Instructions

KUKA KR 1000 1300 titan PA;  KR 1000 L950 titan PA With F Variants Assembly Instructions

Product Description

Composition of Robot System

Robot arm body, control cabinet, smartPAD-2 teaching pendant, motor/data cable, software, optional accessories.

Structure of Robot Arm Body

Belonging to a 6-axis heavy-duty articulated robot, A4 axis is disabled in palletizing mode, while A5 remains parallel to the installation plane; All models only support ground installation. Main components: Inline Wrist built-in wrist (A4-A5-A6), boom, connecting rod arm, rotating column A1, base frame, hydraulic pneumatic balance weight system (2 diaphragm nitrogen accumulators+hydraulic cylinder, offsetting A2 gravity, belonging to pressure vessel), complete set of electrical components (RDC box, MFH multifunctional junction box, pluggable motor cable).

Special structure of F casting plate: Clean compressed air is continuously introduced into the inner cavity of the robotic arm to establish an overpressure of 0.1 bar, blocking the intrusion of dust, coolant, and water vapor; The wrist is coated with a high-temperature resistant silver reflective layer, and the whole machine is equipped with a clear varnish protective layer, which can withstand short-term 180 ℃ thermal radiation.

Available options: A1/A2/A3 axis limit, brake release device, A1-A3/A3-A6 energy supply drag chain system, release device.

Designated use and prohibition of misuse

Designated use: transportation of fixtures and large workpieces for palletizing; Strictly adhere to environmental conditions and maintenance cycles.

Prohibited behaviors: carrying people, climbing scaffolds; Hyperparameter operation; Lack of safety equipment operation; Outdoor, explosion-proof, radioactive, underground mining; Without the permission of KUKA, drilling and modifying the body directly results in the loss of all warranty.

Safety

Legal liability framework: Mechanical arms are semi-finished products; The system integrator is responsible for overall risk assessment, issuing EC compliance statements, and affixing CE markings, while KUKA provides assembly statements. Unauthorized modification of robots results in loss of the right to claim compensation; The responsibility for damage caused by third-party accessories belongs to the integrator. Balance weight belongs to pressure vessels and is controlled by pressure equipment instructions.

Personnel classification: system integrator, operator, debugging and maintenance personnel, cleaning personnel; All personnel must read the complete safety chapter and possess the corresponding qualifications.

Area Definition

Workplace: Robot's reachable range of motion;

Dangerous area=workspace+stopping distance (including external axis), must be physically fenced for protection.

The body comes with built-in protection: mechanical hard limit; Optional adjustable mechanical shaft limit; Brake release device (optional for non powered mobile robotic arm, limited to emergency rescue); The safety warning nameplate of the entire machine must not be torn off or altered.

After hitting the mechanical hard limit, it is prohibited to continue operating and KUKA evaluation must be contacted.

Safety points for each working condition

General safety: Personnel are prohibited from standing under their arms; After a power outage, there is a risk of the robotic arm falling and it must be mechanically supported; The motor casing is hot, pay attention to burns; Pacemaker personnel should be at least 300mm away from the motor/brake; dedicated personnel should be responsible for controlling the teaching pendant; Hardware/program modifications must be tested in T1 mode first; The faulty equipment is powered off, locked, and tagged. After the control cabinet is powered off, the maximum internal high voltage can reach 780V, and it needs to wait for discharge. The arm mechanism must be locked when handling balanced weight pressure vessel operations.

Transportation: Robots must maintain the prescribed transportation posture to avoid impact and vibration.

Start debugging: Change default password when powered on; The robotic arm controller must be paired and cannot be mixed; Complete safety circuit testing; Prevent condensation.

Manual mode T1/T2: T1 is used for teaching demonstration; T2 is only used for high-speed testing and programming is prohibited.

Automatic mode: All protective devices must be in good condition and there must be no personnel in the danger zone before operation.

Maintenance and repair: power off, lock, and verify electricity; ESD anti-static; Refer to MSDS for hazardous chemicals.

Shutdown, storage, and disposal: comply with local regulations.

List the applicable EU directives and international safety standards for this product.

Technical Data

Four major models provide complete parameters in chapters: KR   1000   1300   titan   PA/- F; KR   1000   L950   titan   PA/- F.

Common Basic Information

Repetitive positioning accuracy ISO9283: ± 0.1 mm; IP65, F-version wrist IP67; Noise level<75 dB (A); The base footprint is 2000mm × 2000mm, and the installation hole is C1300.

Environmental conditions: Standard version operates at 10~55 ℃; The F casting plate runs at 5~55   ℃; Storage -40~+60 ℃; F-version pH tolerance is 7.0-9.0.

Cable: Motor cable and data cable can be selected from 7-50 meters, with a maximum of one splicing allowed; Distinguish the connector definitions for KR C4 and KR C5 controllers; Equipotential grounding cable 16   mm ².

Summary of Key Parameters for Each Model

The maximum reach radius of the rated load of the model allows for additional load on the boom

KR   1000   1300   titan   PA 1300   kg 3202   mm 4690   kg Large arm maximum 100   kg

KR   1000   1300   titan   PA-F 1300   kg 3202   mm 4690   kg Maximum boom weight 100   kg

KR   1000   L950   titan   PA 950   kg 3601   mm 4740   kg Maximum boom weight 100   kg

KR   1000   L950   titan   PA-F 950   kg 3601   mm 4740   kg Maximum boom weight 100   kg

Axis parameters: A1 ± 150 °; A2 ‑130°~+17.5°； A3 +62°~+145°； A5 ±118°； A6 ±350°； Provide the maximum rated load speed for each axis; Zero calibration positions A1=0 °, A2=-90 °, A3=90 °, A4=0 °, A5=0 °, A6=0 °; accompanied by side view and top view working envelope drawings.

Mandatory requirement for load verification: both quality and moment of inertia must be verified simultaneously, using KUKA-Load tool, and load data input into the controller; Each model comes with a complete load curve diagram; Wrist flange specification (M16, 16 10.9 grade screws); Provide flange axial force Fa, radial force Fr, overturning moment Mk, and torque Mg for normal operation and emergency stop conditions. Only the boom allows additional loads; Columns and connecting rod arms are not allowed to have additional loads.

Foundation base load: Each model provides vertical force Fv, horizontal force Fh, overturning moment Mk, A1 axis torsional moment Mr (normal value, maximum value); The structural design must adopt the maximum value, and additional vertical forces need to be added to the arm for additional loads.

Nameplate identification: complete machine nameplate, high pressure warning, high temperature warning, balance weight pressure vessel warning, transportation posture identification; The nameplate is prohibited from being torn off or altered.

REACH regulation: SVHC substances of high concern can be found in KUKA Xpert.

Stopping distance and stopping time (safety critical)

Shutdown category: STOP0 (category 0: cutting off the drive and locking the brake); STOP1 (Category 1 Path Controlled Deceleration Shutdown).

Provide stop angle and stop time test data for both KR C4 and KR C5 controllers simultaneously; Distinguish the arm extension ratio (33%/66%/100%), program magnification POV, and different loads; Comes with a large number of curve graphs.

STOP0 has a significant impact on robots and can accelerate brake wear, so it should be used as little as possible; Require annual on-site measurement of stopping distance; The actual stopping distance of multi axis composite motion will increase.

Project Planning

Planning risk warning: Long term temperature/power limit operation, high-frequency reciprocating, static holding, and external process forces will accelerate component wear, and maintenance cycles must be shortened. If necessary, consult KUKA.

Two installation schemes on the ground

Concrete foundation scheme with a fixed base;

Installation of steel structure frame (positioning pin+bolt); The steel structure/concrete base must withstand all maximum foundation loads.

Cable and interface planning: Base end motor cable, data cable interface; Cable laying requirements, cables cannot withstand tension, EMC electromagnetic compatibility; Equipotential grounding is necessary.

F casting version: The customer needs to provide clean and dry compressed air to maintain an overpressure of 0.1 bar in the arm cavity.

Transportation

Forced transportation posture: The manual defines the angles of each axis; The robot must maintain its transport posture throughout the entire transportation process, and it is strictly prohibited to deviate from this posture without being fixed to the base.

Handling method: forklift handling (with forklift holes reserved on the base), or lifting with lifting equipment; Prohibition of savage impact; Provide the overall dimensions for transportation of the entire machine.

Startup and Re Debugging

Installation of concrete foundation: positioning pin of bottom plate in place; Robot lifting and positioning; Tighten the bolts diagonally in steps; After the first 100 hours of operation, tighten the anchor bolts again.

Installation of steel structure frame: assembly of positioning pins, positioning, locking bolts.

Wiring: Distinguish between complete wiring definitions for KR C4 and KR C5 controller motor cables and data cables; Complete equipotential conduction verification.

Mobile manipulator without driving conditions: brake release device, limited to emergency rescue only; ⚠️ The arm will fall in an unpowered state, and the arm must be mechanically supported before operation.

Maintenance

The maintenance cycle is based on standard operating conditions; Heavy load and high-frequency working conditions must shorten the maintenance cycle; Balance weights belong to pressure vessels, and maintenance operations have high-risk risks.

Maintenance Summary: Gearbox Oil Change, Balance Weight System Inspection, Cable Maintenance, Body Cleaning.

A1/A2/A3/A5/A6 gearbox oil drain rinse add specified gear oil;

Pressure inspection and replacement of the balance weight system; The robotic arm must be mechanically locked before starting the homework;

Lubrication of A1 cable components;

Robot body cleaning: Do not use high-pressure water guns or steam cleaning, use solvent-free cleaning agents.

Deep repairs (joint disassembly) that are not within the scope of this manual must be carried out by a KUKA certified engineer.

Maintenance

This manual can perform on-site maintenance items: disassembly and assembly of A4/A5/A6 motors; Inline Wrist built-in wrist disassembly and assembly; Electrical installation circuit instructions.

The disassembly of other components such as the gearbox and balance weight is not covered in the manual, and it is necessary to contact KUKA service.

After the disassembly and assembly of the motor and wrist, the corresponding axis must be re calibrated for zero point.

Shutdown, Storage, and Disposal

Shutdown and disassembly: move to the transport position; power failure; Remove all cable grounding wires; Lift the lifting device off the main body; All electrical connectors are protected against dust.

Long term storage: maintain transportation posture; Dry and dust-free environment without condensation; All interfaces are sealed and protected.

Scrap disposal: Metal recycling of cast aluminum steel; Classify motors and circuit boards as electrical waste; Hydraulic oil, lubricating grease, seals, and balance weight pressure vessels shall be treated as hazardous chemicals; It is prohibited to dismantle the balance weight accumulator without authorization and comply with local environmental regulations.