KUKA KR IONTEC-2 Debugging and Maintenance Guide

KR 50 R2100-2 and KR 50 R2100-2 D01: rated load 50 kg, maximum load 66 kg, maximum arm span 2101 mm, body weight approximately 500 kg, repeat positioning accuracy ± 0.03 mm, protection level IP54, wrist IP67. Controller KR C5 M6/M7 or KR C5 mid-2. The speeds of A1 to A3 are 180 °/s, 150 °/s, 180 °/s, A4 245 °/s, A5 265 °/s, A6 355 °/s, respectively.

KR 50 R2500-2 series: rated load of 50 kg, maximum load of 64 kg, maximum arm span of 2500 mm, weight of approximately 515 kg, repeat positioning accuracy of ± 0.05 mm. The F version weighs approximately 530 kg and has a protection level of IP65. The CR lite version is suitable for cleanrooms and weighs approximately 515 kg.

KR 70 R2100-2 series: rated load of 70 kg, maximum load of 87 kg, maximum arm span of 2101 mm, weight of approximately 500 kg, repeat positioning accuracy of ± 0.05 mm. The F version weighs approximately 515 kg and has a protection level of IP65. The CR lite version has a protection level of IP54 and a cleanroom class of 5.

In terms of environmental conditions, the standard operating temperature ranges from 0 ° C to 55 ° C, the storage and transportation temperature ranges from -25 ° C to 60 ° C, and the humidity level is 3K22. Low temperature operation may require preheating and avoiding condensation and frost. ESD requirements comply with IEC 61340-5-1 and ANSI/ESD S20.20. The noise level is below 80 dB (A). The installation location can be on the ground, ceiling, or wall, depending on the model. The foundation load, flange load, and supplementary load must be calculated according to the model, load center of gravity, and inertia.

Key Points for Planning and Installation

The commonly used installation base with centering for ground installation is R300x400. The base consists of a base plate, chemical anchor bolts, and fasteners, and requires a flat concrete foundation with sufficient bearing capacity. The recommended concrete grade is above C20/25. If there is an insulation layer or leveling layer between the bottom plate and the concrete, it must be in full contact and have sufficient compressive strength. The basic dimensions, margins, and concrete thickness need to be confirmed according to the drawing. Chemical anchor bolt construction must use the same manufacturer's resin and anchor bolt, and diamond drill bits or core drills should not be used. The drilling tools provided by the anchor bolt manufacturer should be prioritized.

Rack installation is used for steel structures and linear sliding tables. The installation surface needs to be cleaned and the hole positions need to be checked. Use two locating pins and eight M20x60-8.8 bolts. During installation, it must be dropped vertically to avoid damaging the positioning pin. Tighten the bolts diagonally alternately and step by step to the specified torque. Robots must be fixed using mounting bases or rack mounted components, and stability is confirmed by integrators or debugging personnel.

The connecting cables include motor cables, data cables, and grounding conductors. Motor cables connect XD20.1 to XD20.6, XD10.1, XD10.2 to XD30, and data cables connect XF21 to XF31 or XF31 to X31. The cable length can be selected from 4 m, 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m, with a maximum of 50 m and a maximum of one extension allowed. The minimum dynamic bending radius for motor cables is 150 mm, and for data cables it is 60 mm. The cables should be installed in metal cable trays, and the motor and data cables should be laid separately to avoid stretching, sharp edges, tool damage, and to prevent tripping risks.

The grounding conductor must be connected using a circular cable terminal, with an M8 nut torque of 15 Nm. The equipotential connection must be checked according to VDE 0100 and EN 60204-1. Interface A1 is located at the rear of the base and includes X30 motor cable, X31 data cable, optional X76 user interface, and AIR1/AIR2 air circuit interface. X76 has 26 pins, rated at 4 A and 300 V, and users need to provide overload and short circuit protection upstream. The maximum pressure of the air circuit is 6 bar, the vacuum is atmospheric pressure minus 0.95 bar, and the outer diameter is 12 mm.

Transportation and Handling

The robot must be placed in the transport position before transportation. The transportation positions of KR 25 R3100-2 are A1 0 °, A2-120 °, A3 160 °, A4 0 °, A5 115 °, A6 0 °. KR 50 and KR 70 series are usually A1 0 °, A2-125 °, A3 150 °, A4 0 °, A5-115 °, A6 0 °. Stability must be maintained during transportation to avoid vibration and impact until the robot is secured.

When handling with a forklift, the fork slot must be installed correctly and completely. Two fork slots are fixed on the rotating column with four M16x35-8.8 hexagon socket bolts and locking washers, with a torque of 195 Nm. Approved M12 lifting accessories are used for lifting, connecting the rotating column and base respectively. The legs are arranged according to the diagram to avoid damaging the robot. The F version may use the lifting plate Iontec-2 F. After transportation, the lifting accessories on the rotating column must be removed. It is prohibited to use cranes to lift robots in other ways.