KUKA Robots KR QUANTEC-2 HO Assembly Instructions

KUKA Robots KR QUANTEC-2 HO Assembly Instructions

HO=Sanitary Oil, heavy-duty robot for hygiene lubrication in the secondary food industry; Model: KR   120   R2700-2   HO, KR   150   R3100-2   HO, KR   240   R2900-2   HO; The body is equipped with a liquid gas energy storage balance cylinder (PED pressure equipment), which is only suitable for ground installation. The base allows a maximum tilt of ± 5 ° and does not support ceiling or wall mounting; Compatible with KR C4 and KR C5 controllers; The gearbox uses food grade lubricant Cassida Fluid GL150, which is different from the Optigear Synt. ALR150 of the regular QUANTEC-2.

Product Description

Body structure: 6-axis serial joint robot; Components: Inline hollow wrist, boom, connecting rod arm, rotating column, base, hydraulic pneumatic balance cylinder, micro RDC electrical components. A1-A3 is equipped with mechanical hard blocks for equipment protection only and cannot be used as personal safety protection. Personnel safety relies on the controller's Safe Robot safety function or optional mechanical axis limit.

Characteristics of HO model: Targeting the secondary food industry, the entire machine is optimized for rust prevention; The gearbox must use Cassida Fluid GL150 food grade sanitary gear oil, and it is strictly prohibited to mix ordinary industrial gear oil.

Installation constraint: Only ground installation is allowed, with a maximum inclination of ± 5 ° for the base; Ceiling and wall hanging are prohibited.

Expected use: Food industry handling, loading and unloading; Environmental conditions must be met.

Prohibited misuse (loss of warranty due to misuse): Climbing and trampling, overloaded operation, carrying people and animals, outdoor exposure, explosion-proof, radioactive, underground mining.

Wrist flange: ISO 9409-1 standard, with different flange aperture specifications for different models; Provide two working conditions for flange axial force, radial force, and overturning moment: normal operation and emergency stop impact.

Additional load: Rotating column, connecting rod arm, and large arm reserved additional load installation interface; The additional load value is not included in the factory foundation load, and the foundation calculation must be additionally superimposed.

Available options: Brake manual release device, A1 hollow shaft cover plate, cable guard, CBS HO filter (exclusive hygiene filter option for HO models).

Technical Data

Covering three models: KR 120 R2700-2 HO, KR 150 R3100-2 HO, KR 240 R2900-2 HO.

Public basic parameters

Protection level: IP65 for the whole machine, IP65/IP67 for the wrist; Noise level is less than 75 dB (A).

Operating temperature 0-55 ℃; Storage -40~60 ℃.

Suitable for KR C4/KR C5; cable 7-50 mm, maximum 50 mm; equipped with 16 mm ² equipotential grounding conductor.

The minimum grade of concrete foundation is C20/25.

Summary of Core Parameters for Aircraft Models

Model rated load, maximum load, maximum arm span, body weight, repeat positioning accuracy

KR 120 R2700‑2 HO 120 kg 167 kg 2701 mm 1069 kg ±0.05 mm

KR 150 R3100‑2 HO 150 kg 220 kg 3100 mm ‑ ±0.05 mm

KR 240 R2900‑2 HO 240 kg 319 kg 2900 mm ‑ ±0.05 mm

Complete output for each model: axis motion range, maximum speed of each axis under rated load, load curve diagram (must be verified by KUKA-Load software for quality, center of gravity, and moment of inertia, and entered into the controller); Wrist flange load (normal, emergency stop impact); Column/boom allows additional load; Foundation load (vertical force, horizontal force, overturning moment, A1 rotational moment); Side view and top view of the work envelope.

Stop distance and stop time

Distinguish between STOP 0 (category 0 uncontrolled emergency stop) and STOP 1 (category 1 controlled shutdown); Provide A1-A3 axis stop angle and stop time curves under different POV program magnifications, extension lengths, and load conditions; STOP   0 is a reference value for simulation and testing, and it is recommended to conduct actual testing on site; It is recommended to check the stopping distance at least once a year for brake wear.

Other

Location of nameplates and warning labels on the main body; REACH regulation information retrieval instructions.

Planning and Design

Provide 3 sets of ground installation plans:

Standard centering base kit S780 (part number 0000-327-118, 58.5 kg): concrete foundation, base plate, locating pin, M24 bolt, chemical anchor bolt; If the foundation is uneven, it is allowed to level the mortar. It is strictly prohibited to pour mortar into the bolt holes. The concrete edge distance and reinforcement requirements are given.

150   mm raised base S780 (part number 0000-338-338261   kg): Elevate the robot body for specific process height requirements.

Rack direct installation kit (0000-310-641, 3.52 kg): directly fixed to the customer's steel structure/slide table; Cylindrical pin+flat pin positioning, 8 M24 bolts are tightened diagonally in steps.

Cable planning

KR   C4: Motor cable X20-X30; Data cable X21-X31;

KR C5: Motor cable XD20-XD30; Data cable XF21-XF31;

Minimum bending radius of cables: motor cables ≥ 150   mm, data cables ≥ 60   mm; motor cables and data cables are routed separately;

The external interface A1 of the main body is located at the rear of the base; Equipotential grounding must be completed in accordance with VDE 0100 and EN 60204-1.

Long term extreme operating conditions (high temperature, high frequency start stop, continuous full load) will accelerate component aging and require a shorter maintenance cycle. It is necessary to consult KUKA services.

Transportation

Mandatory standard transportation posture (unified for all models): A1   0 °; A2‑137°；A3 160°； A4 0°； A5-105 °; A6-0 °, this posture must be maintained throughout transportation.

Transportation method

Forklift: The base comes with a fork slot; Forklifts have a carrying capacity of ≥ 2 tons and can be used for bi-directional forklifts.

Crane lifting: Official lifting tool part number 0000-342-903; Remove tools and pipeline packages before lifting to avoid center of gravity deviation.

Avoid impact and vibration during transportation; Prohibit non certified lifting points from lifting; Provide the center of gravity coordinates of the entire machine.

Startup and Re Debugging

Covering three working conditions: standard centering base ground, 150mm raised base ground, and rack steel structure ground installation.

General installation process: Place the lifting device in place → Clean the installation surface, install the positioning pin → Position the robot → Tighten the M24 bolts diagonally in multiple stages; If necessary, grout and level; Dismantle the transportation lifting equipment.

Wiring specifications

The tightening torque of the grounding M8 nut is 23 Nm;

The tightening torque of the motor cable is 3 Nm; the data cable buckle must be fully locked in place;

The wiring is completed and a complete equipotential conduction test is performed.

Balance cylinder exhaust: After long-term storage, air will accumulate inside the robot. Move the A2 axis ± 30 ° back and forth to release the internal gas and prevent the protective cover from popping open and injuring people.

T1 mode low-speed whole machine trial operation; Provide complete KR C4 and KR C5 motor/data cable pin allocation drawings.

Maintenance

Only allow maintenance items listed in the manual to be executed; The remaining repairs will be handled by KUKA certified engineers; Gearbox specific oil: Cassida Fluid GL150 food grade sanitary gear oil.

Maintenance cycle benchmark

First 100 hours of operation: recheck the torque of all fasteners and bolts;

5000 operating hours or 1 year: Balance cylinder pressure detection, bearing lubrication;

20000 operating hours or 5 years, whichever comes first: replace all gearbox oil; Visual inspection of A1 cable sheath;

The balance cylinder must be replaced as a whole after 10 years (mandatory safety requirement for pressure equipment).

Key points for oil change operation

The gearbox must be in a working hot state; Ventilate and release pressure before draining oil to prevent scalding caused by hot oil splashing; The magnetic drain plug specifies the tightening torque.

If the oil release rate is less than 70% of the rated volume, the gearbox must be flushed; Less than 50% of the rated volume requires multiple washings; Oil change completed T1 low-speed running in, check all seals for leakage.

Main maintenance projects

Drain oil, rinse, and add oil to the gearboxes of A1-A6 shafts; Each axis needs to be placed in a designated position with the oil drain at the lowest point.

Balance cylinder: complete steps for pressure testing (standard pressure), bellows sealing inspection, bearing lubrication, assembly disassembly and replacement.

Whole machine cleaning: Only solvent-free water-soluble neutral cleaning agents are allowed; It is strictly prohibited to use high-pressure steam jet to clean the robot body.

CBS HO Filter (Exclusive for HO Models): Installation, Maintenance, and Filter Element Replacement Process.

Maintenance

High risk maintenance operations; Before disassembling the A2/A3/A5/A6 motors, it is necessary to use a sling to mechanically lock the arm body and lock the balance cylinder; The failure of the power outage brake and the accumulation of energy in the balance cylinder will cause the arm to fall under its own weight, posing a risk of fatal compression.

General process for motor replacement: Disconnect the motor from the encoder connector; Remove the bolts; Apply Microlube GL261 lubricating grease to the involute spline of the new motor; Replace all O-rings with new ones; Do not install the motor at an angle; Tighten the bolts diagonally in stages; Restore the connector.

Motor replacement completed: The axis must undergo mastering zero calibration; T1 low-speed test run.

Includes the complete set of disassembly and assembly steps for A1-A6 motors, A4/A5 connecting shafts, and Inline hollow wrist assembly; The weight of the wrist assembly is approximately 100 kg, and a crane must be used.

Electrical system: micro RDC box, complete set of electrical schematics and wiring diagrams for motor, brake, temperature, and encoder.

Priority should be given to using KUKA original spare parts for spare parts; Return of faulty parts within the warranty period requires filling out a repair report.

Shutdown, Storage, and Scrap Disposal

Dismantling process: The robot moves to the standard transport posture; Emergency stop, lock and power off; Dismantling tools and fixtures; Disconnect the cable and ground it; Loosen the M24 bolts on the base, lift the body vertically, and protect the positioning pin.

Storage conditions: The storage location should be dry and dust-free, avoiding condensation and direct sunlight; Storage -40~60 ℃; Clean and cover the body, remove tool accessories; Electrical joint sealing protection requires the placement of desiccants.

Scrap and dismantle

Classification and recycling of cast aluminum, cast steel, steel, copper cables, and electrical components; Waste gear oil should be treated as hazardous waste.

Before dismantling and scrapping the balance cylinder, it must be thoroughly depressurized; Internal storage of high-pressure nitrogen gas poses a risk of explosion if not depressurized.

Options

Brake manual release device: Emergency manual joint movement in case of power failure, limited to personnel rescue and escape.

After using the release device to move the joint, all axes must be recalibrated and the brake function must be fully tested to prevent injury from collision.

A1 hollow shaft cover plate: installation, cleaning and maintenance steps.

Cable bundle cover assembly.

CBS HO Filter (exclusive to HO models): Food hygiene robot filter component, installation, and filter element replacement operation.