KUKA KR 700 PA/KR 700 PA Arctic Installation Guide

KUKA KR 700 PA/KR 700 PA Arctic Installation Guide

Product Description

System composition

Robot arm body, KR C2/KR C4 control cabinet, KCP handheld programming unit, connecting cables, software, optional accessories.

Arctic is a low-temperature specialized model, with different mechanical structure, balance weight, lubricating grease, and electrical components from the standard version.

Structure of Robot Arm Body

4-axis parallelogram stacking configuration; Main components: wrist, forearm, boom, turntable A1, base frame, hydraulic pneumatic balance weight system (to counteract the weight of A2 boom, including diaphragm accumulator, hydraulic cylinder, pressure gauge, safety valve, nitrogen filling), complete set of electrical components.

Wrist: Single axis wrist A6 with measuring tube, used for mechanical zero calibration; Flange installation tool.

Small arm/large arm: parallel linkage mechanism, maintaining flange plane posture; Configure mechanical hard limit buffer blocks.

Rotary table: realizes A1 rotation, integrates motor, and reserves forklift handling socket.

Base: The entire machine is installed on a base, which integrates a junction box and a drag chain interface.

Optional configurations: A1 axis limit, drag chain system (A1-A3, A3-A6), free rotation device (no drive manual rotation motor).

Designated use and prohibition of misuse

Designated use: for transporting fixtures, palletizing and transporting workpieces, environmental conditions and maintenance cycles must be followed.

Prohibited behaviors: carrying people, climbing scaffolds; Hyperparameter operation; Lack of protective operation; Outdoor, explosion-proof, radioactive, and underground use; Unauthorized drilling/modification of the body structure will result in the loss of all warranty.

Robots are semi-finished products and are not allowed to operate independently when powered on. The integrator needs to complete a complete equipment risk assessment and CE compliance declaration.

Safety

Legal responsibility: KUKA provides assembly declaration; The system integrator is responsible for overall risk assessment, issuing EC conformity statements, and affixing CE markings; Unauthorized modification of the robot results in the loss of the right to claim compensation, and the responsibility for damage caused by third-party accessories belongs to the user.

Personnel classification: operators, system integrators, debugging, operation, maintenance, and cleaning personnel; All personnel must read the safety chapter and possess the corresponding qualifications.

Area Definition

Workplace: The robot can reach the range of motion;

Dangerous area=workspace+stop travel, must be physically fenced for protection;

Protective zone: outside the danger zone.

The body comes with built-in protection: mechanical hard limit; Optional mechanical shaft limit; Free rotation device (optional, only for emergency rescue, the motor brake may be damaged after use, requiring motor replacement and re zero calibration); The safety nameplate of the entire machine is prohibited from being torn off or altered.

After hitting the mechanical hard limit, the robot cannot continue to operate and must contact KUKA for evaluation.

Safety measures for each working condition

General safety: Personnel are prohibited from staying under their arms; After a power outage, there is a risk of the arm falling and mechanical support is necessary; The casing of the motor is running at high temperature and requires protection; Pacemaker personnel are at least 300mm away from the motor; dedicated personnel are responsible for controlling the teaching pendant; Modifying programs/hardware requires T1 low-speed mode testing; The faulty equipment is powered off, locked, and tagged. After the control cabinet is powered off, a maximum high voltage of 780V can be retained inside for several minutes.

Transportation: It is necessary to maintain the transportation posture and avoid impact and collision.

Put into operation: Change the default password of the controller; 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 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; Balance weight belongs to pressure equipment, with high-pressure nitrogen gas, and there is a risk of explosion and shock during operation; Refer to the MSDS safety data sheet when handling hazardous chemicals.

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

List the EU directives and international safety standards that this product complies with.

Technical Data

Basic Parameters

Table

Project KR   700   PA

4 axes (A1/A2/A3/A6)

Maximum arrival radius 3320   mm

The self weight is about 2850 kg; the transport frame weighs 212 kg

ISO9283 repeatability accuracy ± 0.08 mm

Protection level body, wrist IP65

Noise<72 dB (A)

Installation posture is only for ground installation; Base footprint circular

environmental conditions

Standard version operation: 0~+55   ℃; Storage -40~+60 ℃;

Operation of Arctic low-temperature models: -30~+10   ℃;

The humidity meets the EN 60721-3-3 3K3 level.

Cable: optional 15/25/35/50   m; maximum allowable splicing once; An equipotential grounding wire must be added to cables larger than 25 meters; Provide the bending radius of the motor and data cable.

Axis motion parameters

Axis software motion range, rated load, maximum speed

A1 ±185° ‑

A2 +10° ~‑120° ‑

A3 ‑10° ~+150° ‑

A6 ±350° ‑

The actual itinerary of A3 is constrained by the position of A2; The manual comes with side view and top view work envelope drawings.

Load parameters

The rated load of the wrist flange is 700 kg, with a maximum total load of 750 kg; the rated center of gravity is Lxy=350 mm, Lz=300 mm; the maximum allowable moment of inertia is 350 kg · m ².

Additional load: The forearm allows a maximum additional load of 50 kg; Additional loads are not allowed on the turntable and upper arm. Please provide a drawing of the installation holes for the additional loads on the lower arm.

Wrist flange specifications: similar to DIN/ISO 9409-1-A200; 23 × M12-10.9 screws; Positioning pin 12H7; with Ø 60   mm hollow through-hole.

Provide the axial force Fa, radial force Fr, overturning moment Mk, and torque Mg of the flange under normal operation and emergency stop conditions.

The load mass and moment of inertia must be verified simultaneously using the KUKA-Load tool, and the load parameters must be entered into the controller. The manual comes with a load curve diagram.

Foundation Base Load (Ground)

The structural design must use the maximum load value, and additional loads need to be superimposed. |Project | Normal | Maximum | | -------- | | Vertical force Fv | 44500   N | 63000   N | | Horizontal force Fh | 12500   N | 19000   N | Overturning moment Mk | 77000   Nm | 83000   Nm | A2 axis torsional moment Mr | 17500   Nm | 43000   Nm|

Nameplate Identification

Multiple safety nameplates are arranged on the robot, including high pressure warning, high temperature warning, axle fixing reminder, balance weight pressure hazard, transportation posture identification, and machine model nameplate; The nameplate is prohibited from being torn off or altered.

REACH Regulation

Search KUKA Xpert product library for SVHC high concern substance information.

Stopping Travel and Stopping Time (Safety Critical)

Shutdown category: STOP   0 (category 0 cuts off the drive, locks the brake); STOP   1 (Category 1 path controlled deceleration stop).

Assessment objects A1/A2/A3; The stopping stroke of multi axis compound motion will increase.

The manual provides different extension lengths (33%/66%/100%), different program magnifications POV, stop angles under different loads, and stop time curves.

The STOP0 value serves as a reference for testing and simulation; The brake wears out with the number of STOP0 triggers; Require annual on-site testing to stop travel.

Project Planning

Planning risk warning: Long term temperature limit operation, high-frequency short cycle reciprocating, static loading, external process forces will accelerate component wear, and maintenance cycles need to be shortened. If necessary, consult KUKA. Automatic shutdown protection for over limit robots.

Three ground fixing schemes: 1) Foundation fixing device -175mm: concrete foundation thickness ≥ 175mm, C20/25 concrete, chemical anchor bolt components; Provide drawings of the bottom plate dimensions and concrete edge thickness. 2) Foundation fixing device -200mm: concrete thickness ≥ 200mm; chemical anchor bolt scheme. 3) Rack fixing device: steel structure/sliding platform bracket; Sales+sword shaped sales positioning; 8 M24 bolts; Steel structures must withstand all maximum foundation loads.

It is prohibited to lay isolation layers or mortar layers between the bottom plate and concrete, and only fill the gaps with finishing mortar.

Interface cable planning

Base A1 interface: motor cable X30, data cable X31; Drag chain interface X76; Grounding terminal.

Cable laying: Separate metal cable trays to meet EMC requirements, and cables cannot withstand tensile forces; Working temperature -10~+70 ℃; Equipotential grounding is necessary.

Distinguish the junction boxes and plug definitions corresponding to KR C2 and KR C4 control cabinets.

Transportation

Standard transport posture (must be strictly followed): A1=45 °, A2=-120 °, A3=150 °, A6=0 °.

Special low transport posture: Remove A2 buffer, A2=-130 °; the buffer must be restored after transportation is completed.

Handling method: ① Forklift handling (using the original forklift socket of the turntable, forklift rated ≥ 3.5 tons); ② Optional lifting equipment; ③ The whole set is fixed on the transport rack for transportation.

Provide the overall dimensions and center of gravity position drawings for the transportation of the entire machine; When not fixed to the base, the robot must maintain its transport posture throughout the entire process.

Operation and Re operation

Three installation processes: 175mm concrete foundation, 200mm concrete foundation, and steel structure rack installation; The horizontal deviation of the bottom plate is less than 3 °; Use filling mortar to treat gaps; Chemical anchor bolts must wait for complete solidification.

Robot lifting and positioning, pin positioning; Tighten 8 M24 bolts diagonally in steps, with a final torque of 640 Nm; after the first 100 hours of operation, the anchor bolts must be tightened again.

Wiring operation: Distinguish the complete wiring diagram and pin definitions of motor cables and data cables between KR C2 and KR C4; Complete equipotential conduction verification.

Non driving energy mobile manipulator: using optional free rotation device; For emergency rescue only, if the motor brake is damaged after use, the motor must be replaced and all shafts must be recalibrated.

Before starting up, handle the balance weight exhaust valve protective cover: move the A2 axis to release the accumulated pressure inside and prevent the protective cover from popping out at high speed and injuring people.

Maintenance

The maintenance cycle is based on standard operating conditions; Frequent short stroke operating cycle shortened; The lubricating grease and hydraulic oil for the Arctic low-temperature model are different from the standard version. 

|Cycle | Homework Content | Consumables |

| First 100 hours | Tighten the foundation bolts to 640 Nm |

| 5000 hours (latest 1 year) | Add LGEP 2 grease to multiple bearings | LGEP 2 grease | 

| 5000 hours (latest 1 year) | Check the pressure and safety valve lead seal of the balance weight system | Standard Version: Hyspin ZZ 46; Arctic: Shell Spirax S1 ATF TASA hydraulic oil | 

| 20000 h (latest 5 years) | A1/A2/A3/A6 gearbox oil change | Standard version Optigear Synt. ALR 150; Arctic: Alphasym T32 | 

| Year 10 | Overall replacement of balance weight assembly |

Detailed maintenance steps: Drain oil from each shaft gearbox, rinse, and add oil; Balance weight pressure detection, disassembly and replacement of the entire set of balance weights (approximately 95 kg, with high-pressure nitrogen, high-risk operation, requiring lifting equipment and clamping sleeve fixtures).

Cleaning: Do not use high-pressure water guns or steam cleaning; Only solvent-free water-soluble cleaning agents can be used; Prevent liquid from seeping into mechanical and electrical gaps.

Maintenance

Manual description of on-site executable maintenance: disassembly and installation process of A1/A2/A3/A6 motors; Including requirements for tooling and lifting equipment, apply lubricating grease Microlubricant GL 261 to the tooth surface, and calibrate the corresponding shaft zero point after installation.

Other complex repairs such as gearbox and balance weight disassembly must be carried out by KUKA certified engineers. Provide complete schematic diagrams of motor cables, data cables, and grounding system wiring for KR C2 and KR C4 systems.

Stopping Operation, Warehousing, and Disposal

Shutdown and disassembly: move to the transport position; power failure; Dismantle all cables; Lift the lifting device off the main body; All electrical connectors shall be protected against dust.

Long term storage: maintain transportation posture; The environment is dry, dust-free, and free of condensation; All interfaces are sealed and protected.

Scrap disposal: metal recycling of cast aluminum steel; Classification of motors and circuit boards as electrical hazardous waste; Hydraulic oil, lubricating grease, and seals should be treated as hazardous chemicals; It is prohibited to dismantle the balance weight pressure vessel without authorization.