KUKA KR IONTEC-2 Debugging and Maintenance Guide

KUKA KR IONTEC-2 Debugging and Maintenance Guide

KR IONTEC-2 Product Positioning and System Composition

KUKA KR IONTEC-2 is a series of six axis articulated industrial robots designed for medium load handling, processing, assembly, and material transfer scenarios. This product family covers KR 25 R3100-2、KR 50 R2100-2、KR 50 R2100-2 D01、KR 50 R2100-2 CR lite、KR 50 R2500-2、KR 50 R2500-2 D01、KR 50 R2500-2 F、KR 50 R2500-2 CR lite、KR 70 R2100-2、KR 70 R2100-2 D01、KR 70 R2100-2 F、KR 70 R2100-2 CR lite  Waiting for the model. Different suffixes represent different application orientations: D01 usually corresponds to a specific drive chain configuration, F is the casting environment enhanced protection version, CR lite is the cleanroom version, the F version has a protection level of up to IP65, and CR lite can meet ISO 14644-1 Class 5 cleanroom requirements.

A complete robot system not only includes a robotic arm, but also a robot controller, connecting cables, teaching pendant, system software, options, and accessories. Common controllers include KR C5 mid-2, KR C5 M6/M7, etc. The teaching pendant can be KUKA smartPAD-2, smartPAD pro, or used with a tablet or laptop paired with KUKA smartPLUG on KR C5-2 and KR C5 micro-2, or with a laptop solution without smartPLUG.

The mechanical arm body consists of a base, a rotating column, a connecting rod arm, an arm, an inline wrist, a cable group, etc. The A1 axis is rotated by a rotating column, the A2 axis drives the connecting rod arm, the A3 axis connects the arm, and the A4 to A6 form a three-axis inline wrist. Each axis is equipped with measuring devices, which can be used to complete mechanical zero calibration through electronic probes. The wrist flange is used to install end effectors, and the interface size is close to ISO 9409-1:2004. Install motor cables, data cables, grounding conductors, and energy supply system interfaces on the base.

Security logic and compliance prerequisites

KR IONTEC-2 belongs to partially completed machinery and must be integrated into a complete system and meet the EC Machinery Directive before it can be put into operation. The system integrator is required to complete risk assessment, implement safety functions, install safety protection devices, and issue a complete EC compliance statement for the system. The robot controller is marked with CE, but the robotic arm body must form a compliance system together with the controller, outer shaft, tools, and software.

The core concepts of the safety chapter include: axis range, stopping distance, workspace, danger zone, safety zone, stopping category, T1 manual slow speed, T2 manual high speed, external axis, system integrator, and user. The danger zone is determined by both the workspace and the stopping distance, where the stopping distance is equal to the reaction distance plus the braking distance. The safety protection device must be located outside the danger zone, but the robot stopping process may still be completed within the danger zone. Therefore, safety doors, gratings, scanners, etc. must be arranged according to the risk assessment results.

In terms of personnel requirements, operation, maintenance, and debugging personnel must undergo training and be able to identify tasks and potential hazards. Users should fulfill their supervisory obligations, conduct regular safety briefings, and provide personal protective equipment. The system integrator is responsible for installation, connection, risk assessment, implementation of safety functions, CE marking, and preparation of system operation manuals.

In manual mode, T1 is used for setup, teaching, programming, and program validation. New or modified programs must be tested under T1 first. If it is necessary to work within a safe zone, the operator should be able to observe the danger zone and evacuate at any time; When multiple people enter, each person must have an enabling device, and everyone must maintain visual and eye contact. T2 is only used for testing that requires speeds higher than T1, and teaching and programming are not allowed under T2. Automatic mode requires all safety devices to be available, no one in the danger zone, or to meet the EN ISO 10218 collaboration requirements.

When maintaining and repairing, priority should be given to working outside the danger zone. When entering the danger zone, the robot should be turned off and locked with a tag, and if necessary, it should be done under T1. The emergency stop device must remain effective. If the security function is temporarily cancelled, it must be restored immediately after the work is completed. After the robot controller is powered off, some components may still carry a voltage of 50V to 780V for several minutes, and must wait for discharge and comply with ESD regulations. For controllers with transformers, the transformer should be disconnected before operation. The counterweight system, gas spring, hydraulic accumulator, etc. also need to be inspected according to the pressure equipment regulations.

Quick search of key technical data

KR 25 R3100-2: Rated load 25 kg, maximum load 33 kg, maximum arm span 3100 mm, body weight approximately 510 kg, repeat positioning accuracy ± 0.05 mm, protection level IP54, wrist IP67, controller KR C5 mid-2. A1 has a motion range of ± 185 °, A2 is -175 °/+60 °, A3 is -110 °/+165 °, A4 ± 180 °, A5 ± 125 °, A6 ± 350 °. Speed under rated load: A1 180 °/s, A2 150 °/s, A3 180 °/s, A4 335 °/s, A5 420 °/s, A6 592 °/s.

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.

Startup and Debugging Process

Before starting, it is necessary to confirm that the installation location is accessible, the robot is in the transport position, the basic dimensions are qualified, the surface is flat, and the connecting cables and grounding conductors have been laid. If the ground is uneven, leveling compound can be used, but the bolt area must not be covered by leveling material. When installing the base, first clean the foundation, install the positioning pin, fix the bottom plate to the robot with M20x60-8.8 bolts, and then lift it to the installation position. Anchor bolt construction shall follow the manufacturer's instructions for drilling, cleaning, gluing, and curing. For rack installation, first clean the installation surface, check the hole position, install the positioning pin, vertically lower the robot, insert eight M20x60-8.8 bolts, and tighten them diagonally step by step.

When making electrical connections, first connect the grounding conductor, and then connect the motor cable and data cable. The connector must be locked, the motor connector should have a clicking sound, and the red ring should not be visible. The locking button can be rotated 90 degrees to prevent accidental release. Then check the equipotential connection and enter the robot installation position in WorkVisual, which defaults to ground. Finally, install the tool and complete the startup according to the controller and system software instructions.

Maintenance and Lubrication

The maintenance cycle may vary slightly depending on the model. Usually check the tightening torque 100 hours after startup; Visually inspect the cable assembly every 5000 hours, and if any damage or cracks are found, KUKA Service should replace them; Replace gear oil every 20000 hours or 5 years. A1 gearbox is about 4.55 L, A2 is about 1.75 L, A3 is about 1.06 L, A4 is about 0.22 L, A5 is about 0.40 L, A6 is about 0.12 L, using Optigear Synt. ALR 150. Cable group A1 needs to be coated with Optitemp RB2 grease, approximately 0.03 kg. If the oil temperature exceeds 60 ° C, the maintenance interval should be shortened. It is recommended to conduct an overall inspection every 7 years or when there is a change in usage.

Before maintenance work, it is necessary to ensure that the maintenance point is accessible and remove tools and attachments. The robot must be fixed by emergency stop. If working while powered on, it can only move at a reduced speed and can be stopped urgently at any time. After maintenance, all security functions need to be restored and functional testing should be conducted. Only auxiliary materials and consumables approved by KUKA can be used, non approved materials may cause premature wear.

Discontinuation, storage, and disposal

When not in use, first move the robot to the transport position, install the fork slot, disconnect the peripheral connections, motor cables, data cables, and grounding conductors, loosen the eight M20 bolts, lift it vertically, and transport it away. Be careful not to damage the locating pin. If the robot is not reinstalled temporarily, it should be cleaned, rust proofed, electrical interfaces sealed, hoses sealed, covered with plastic film, and sealed to prevent dust at the base. If necessary, desiccants should be placed. The storage environment should be dry, dust-free, avoid temperature differences, wind, condensation, and direct sunlight, and maintain an allowable temperature range.

Disposal can be classified by material: aluminum alloy is used for wrists, arms, connecting rods, and rotating columns; Copper is used for cables; Cast steel is used for the base; Steel is used for gearboxes, screws, washers, and covers; Electronic components such as RDC and EDS are treated as electronic waste; The motor is not disassembled for processing. Plastics include ABS, ETFE, FKM, NBR, PA, PE, PU, PUR, etc. Gear oil, adhesives, sealants, and lubricants need to be handled according to the safety data sheet.

Release device and non driving energy movement

The release device is used for manually moving the robotic arm after accidents or malfunctions, mainly covering motors A1 to A3, and is only used for abnormal and emergency situations, such as rescue personnel. The device includes a ratchet and an indicator board, which indicate the direction of rotation and the direction of movement of the robotic arm. Before use, remove the M4x8 screws from the motor cover, pry open the cover plate in the slot with a flathead screwdriver, and push the release device or 12 mm open-end wrench onto the motor to overcome the brake and load resistance and move the shaft. After operation, it is necessary to clean the motor and cover plate, reinstall the cover plate, and tighten the screws. Due to the possibility of losing zero point when moving the rear axle without driving energy, it is necessary to re master all axles, perform brake tests, and test run under T1.

Common troubleshooting ideas

The troubleshooting of KR IONTEC-2 should follow the principle of "safety first, power-off confirmation, record analysis, and step-by-step verification". Firstly, trigger the emergency stop, turn off the main switch and lock and tag, and confirm that the system has been discharged. Then check the controller diagnostic information, safety circuit status, drive enable, encoder, RDC communication, and cable connections. Common issues include: incomplete locking of connectors, small bending radius of cables, damage to motor or data cables, poor grounding, missing equipotential connections, condensation, dust, oil stains, high temperatures, incorrect input of load data, tool center of gravity and inertia exceeding limits, mechanical end collision, brake wear, gearbox oil leakage, abnormal counterweight system, loose foundation bolts, etc.

If the robot experiences unexpected movements, load data, program points, external axes, safety configurations, and brake test results should be checked. If the stopping distance becomes longer, check the brake, load, speed, and maintenance status. If there is a communication interruption, check the X30, X31, XF21, XF31 connectors and cable shielding. If zero point loss occurs, the battery should be checked RDC、 Encoder and Mastering Status. If there is abnormal noise or vibration, the gearbox oil level, bearings, flanges, and supplementary load should be checked. Any abnormal safety function must be immediately shut down, repaired, and re verified.

Repairs beyond the scope of maintenance must be completed by KUKA trained personnel. When contacting customer service, the robot model, serial number, controller model, system software version, fault description, frequency of occurrence, diagnostic package, application, and external axis information should be provided. KUKA Xpert can query stopping distance and time, spare parts, circuit diagrams, and safety data sheets.