KUKA QUANTEC-2 HO Maintenance Guide

KUKA QUANTEC-2 HO Maintenance Guide

KUKA KR QUANTEC-2 HO is a six axis articulated robot designed for secondary processing areas in the food related industry, covering three models: KR 120 R2700-2 HO, KR 150 R3100-2 HO, and KR 240 R2900-2 HO. HO stands for Sanitary Oil, which means that the series has replaced the standard QUANTEC-2 platform with food grade gear oil, light gray moving parts coating, and added CBS HO filters and other configurations suitable for food environments. For food factory equipment engineers and system integrators, mastering their oil change specifications, balancing cylinder inspections, CBS filter maintenance, motor replacement, and common fault troubleshooting are key to ensuring production line hygiene compliance and stable equipment operation.

Model positioning and the uniqueness of the food industry

The rated load of KR QUANTEC-2 HO covers 120 kg, 150 kg, and 240 kg, with maximum arm spans of 2701 mm, 3100 mm, and 2900 mm, respectively. The body weighs approximately 1069 kg, 1105 kg, and 1120 kg, with a pose repeatability accuracy of ± 0.05 mm, a protection level of IP65, and an optional wrist protection level of IP67. The noise level is below 75 dB (A). The installation position is on the ground, with a permissible inclination angle of ± 5 °. The base is black RAL 9005, and the moving parts are light gray RAL 7035, making it easy to identify the cleanliness status in food environments.

The most significant difference in the HO version is the gear oil. The standard model uses Optigear Synt. ALR 150, while the HO model must use Cassida Fluid GL150. This oil is a food grade lubricant, and the gearbox or base is labeled with Cassida Fluid. Standard gear oil should not be mixed during maintenance. Robots must not come into direct contact with food and are only used for secondary areas such as handling, picking up, and packaging in food related environments. If used for main food processing or direct contact with food, the system integrator needs to re evaluate the risks and take additional protective measures.

Quick search of key data

KR 120 R2700-2 HO has a rated load of 120 kg, a maximum load of 167 kg, and a workspace of 56.3 m ³. Axis motion range: A1 ± 185 °, A2-140 °/-5 °, A3-120 °/168 °, A4 ± 350 °, A5 ± 125 °, A6 ± 350 °. Rated load speed: A1 120 °/s, A2 115 °/s, A3 120 °/s, A4 190 °/s, A5 180 °/s, A6 260 °/s. Zero calibration positions: A1-25 °, A2-100 °, A3 100 °, A4 0 °, A5 0 °, A6 0 °.

KR 150 R3100-2 HO has a rated load of 150 kg, a maximum load of 220 kg, and a workspace of 86.3 m ³. Speed: A1 105 °/s, A2 107 °/s, A3 114 °/s, A4 190 °/s, A5 180 °/s, A6 260 °/s. KR 240 R2900-2 HO has a rated load of 240 kg, a maximum load of 319 kg, and a workspace of 68 m ³. Speed: A1 103 °/s, A2 94 °/s, A3 100 °/s, A4 170 °/s, A5 129 °/s, A6 206 °/s.

When operating at an ambient temperature of 0 ° C to 55 ° C, and during storage and transportation at -40 ° C to 60 ° C. Low temperature operation may require preheating and avoidance of condensation and frost. ESD requirements comply with IEC 61340-5-1 and ANSI/ESD S20.20. Flange load, foundation load, and supplementary load must be calculated according to the model, load center of gravity, and inertia. Load data must be input into the controller, otherwise trajectory planning and dynamic performance will deviate from expectations.

Transportation, installation, and connection

Before transportation, the robot must be placed in the transportation position: A1 0 °, A2-137 °, A3 160 °, A4 0 °, A5-105 °, A6 0 °. Avoid vibration and impact during transportation until the robot is firmly fixed. When transported by forklift, there are four fork slots on the base, and the forklift can start from front and back. The minimum load capacity of the forks is about 2.0 tons. When lifting, use a lifting device to connect the two front fork slots and the rotating column. The legs are arranged according to the diagram, and the G3 legs are equipped with adjustable chains that need to be adjusted to the robot's vertical suspension. Do not use a crane to lift in any other way.

The ground installation adopts a centered installation base S780, and the recommended concrete grade for the foundation is C20/25. There should be no insulation or leveling layer between the bottom plate and the concrete. Chemical anchor bolt construction must use the same manufacturer's resin and anchor bolt, and diamond drill bits or coring drills are not allowed. During installation, first fix the base plate and positioning pin, then place the robot on the foundation, drill 12 anchor bolt holes, install chemical anchor bolts, and connect the cables after curing. Tighten 8 M24x65-8.8 bolts step by step to the specified torque. Optional 150mm mounting base S780 with 16 chemical anchor bolts.

Rack installation is used for steel structures, mounting brackets, or KUKA linear guides. The installation surface needs to be prepared according to the diagram, using two locating pins and eight M24x65-8.8 hexagonal bolts, and tightened step by step. The connecting cables include motor cables, data cables, and grounding wires. KR C4 uses Han 16HP motor cable from X20 to X30 and Han 3A Q12 data cable from X21 to X31. KR C5 uses 6 motor plugs XD20.1 to XD20.6, 2 brake plugs XD10.1 and XD10.2 to XD30, and data cables XF21 to XF31. The cable length can be selected from 7 m to 50 m, with a maximum of 50 m and a maximum of one extension allowed. When fixed laying, the bending radius of motor cables should not be less than 150 mm, and that of data cables should not be less than 60 mm. The grounding wire should use a circular cable terminal with an M8 nut torque of 23.0 Nm.

Oil change and lubrication

The oil change cycle of the HO type is similar to that of the standard type, but the oil type is different. Maintenance table regulations: After 100 hours of operation, check the fastening bolts with a torque of 640 Nm; lubricate the balance cylinder bearings every 5000 hours or at the latest 1 year, using approximately 10 cm ³ of LGEP 2 grease; Check the balance cylinder pressure every 5000 hours; Replace gear oil every 20000 hours or no later than 5 years. If there is frequent short distance exercise, the maintenance interval can be shortened to 3000 hours.

Oil change volume: A1 about 5.70 L, A2 about 2.10 L, A3 about 1.40 L, A4 about 2.10 L, A5/A6 about 1.40 L (wrist ZH210) or 1.90 L (wrist ZH300). All use Cassida Fluid GL150. When changing the oil, the gearbox should be at operating temperature, and the discharge amount depends on the discharge time and oil temperature. The refilling amount must be consistent with the emission amount. If the emission amount is less than 70% of the specified oil amount, it needs to be flushed once with discharge oil; If it is less than 50%, rinse twice. Move the axis within the full axis range at a jog speed during flushing.

The tightening torque of the magnetic plug is 25 Nm for A1, 20 Nm for A2, 20 Nm for both the upper and lower parts of A3, 40 Nm for both the upper and lower parts of A4, and 20 Nm for A5/A6. When operating, pay attention to hot oil burns and oil chamber pressure, and exhaust before discharging. When cleaning robots, neutral cleaning agents must be used, which are solvent-free, water-soluble, non flammable, steam free, refrigerant free, chlorine free, and non strong acid and alkali free. Do not use high-pressure cleaners, do not use compressed air to clean bearings and sealing points, and prevent cleaning agents from entering electrical or mechanical components.

Balance cylinder inspection and replacement

The balance cylinder is a hydraulic and pneumatic component between the turntable and the connecting rod arm, used to reduce the torque of shaft 2. During inspection, manually run A2 to -90 °, wait for 1 minute, press emergency stop, and read the pressure gauge. KR 120 R2700-2 HO and KR 150 R3100-2 HO should have a pressure of 150 bar ± 15 bar at 20 ° C; KR 240 R2900-2 HO should be 176 bar ± 15 bar. If the pressure is abnormal, a dedicated pressure gauge should be used for retesting and KUKA service should be contacted. Check if the attachments are dirty, damaged, or leaking, and clean or replace them if necessary. Check the bellows and clamps, and replace them by professionals if necessary.

Replacing the balance cylinder is a high-risk operation. The balance cylinder weighs about 40 kg and is under pressure. Wear protective gloves and secure with slings and cranes during homework to prevent falls and accidental movements. The steps include: loosening the threaded clamp and pushing back the corrugated pipe; Move the connecting rod arm forward and install it into the clamping sleeve; Move the connecting rod arm in the negative direction to clamp the bushing; Fix the balance cylinder and connecting rod arm with a sling; Remove the cover plate and turntable bolts; Use a bolt fastener and a bolt puller to remove the bolt; Push the balance cylinder out of the turntable bolt; Lift it to a safe location. Install the new balance cylinder in reverse order. After completion, check the pressure and put it back into operation.

CBS HO Filter

CBS HO filter is a ventilation filter installed on the balance weight, used for balancing cylinder breathing in food environments. The maintenance schedule stipulates a visual inspection every 5000 hours, and if the filter turns black, it should be replaced. Open the valve cover during installation, insert the straight male coupling and reducing coupling, tighten and install the ventilation filter. When disassembling, first remove the ventilation filter, loosen the coupling, and close the valve cover. After replacement, it is necessary to test run in T1 mode and observe for any abnormalities. Filter blockage can cause poor breathing in the balance cylinder, which may lead to pressure fluctuations or leaks. Therefore, food factories should include it in regular inspections.

Motor and wrist replacement

Before replacing the motor, it is necessary to comply with electrical safety regulations: cut off the power supply, lock and prevent restart, confirm no voltage, ground and short-circuit, cover or isolate adjacent live parts. Simultaneously press the emergency stop button to prevent the robot from accidentally moving. When the motor is just stopped, the surface temperature is high and protective gloves should be worn; There is a risk of crushing during disassembly and assembly, and protective gloves should also be worn.

A1 motor replacement: Remove XM1 and XP1, unscrew 4 M12x25-8.8 screws, and lift out the motor. Clean the teeth before installing the new motor, apply a small amount of Microlube GL 261, and check the O-ring. Install the screws and tighten them diagonally step by step. Connect plug, zero point calibration, T1 test.

A2 motor replacement: First, fix the connecting rod arm with a sling, remove XM2 and XP2, hang A2 motor, unscrew 4 M12x25-8.8 screws, and pull out the motor. Clean the teeth, apply lubricating grease, install screws, and tighten diagonally during installation. Connect the plug, remove the stopper, calibrate the zero point, and conduct T1 testing.

A3 motor replacement: Secure the robot arm with a sling, remove XM3 and XP3, suspend the A3 motor, unscrew 4 M12x25-8.8 screws, and pull out the motor. Pay attention to the installation of protective tube A3. Clean the teeth, apply lubricating grease, install screws, and tighten diagonally during installation. Connect the plug, remove the stopper, calibrate the zero point, and conduct T1 testing.

A4 and A5 motor replacement: Remove XM4/XP4 or XM5/XP5, unscrew 4 M8x25-8.8 screws, and take out the motor and connecting shaft. Check the compression spring. If there is a retaining ring when removed, it must not be reused. Clean the teeth during installation, apply lubricating grease, push the connecting shaft into the motor shaft, install screws, and tighten diagonally. Connect the plug, zero point calibration A4, A5, A6, T1 test.

The replacement of A6 motor is the most complex, requiring the disassembly of A4 and A5 motors, connecting shafts, wire harness wrist, and then A6 motor. The harness wrist weighs approximately 100 kg and must be securely fixed with a crane. During installation, follow the reverse order and ensure that the motor connector is located diagonally in the lower left corner, and that the compression spring is in good condition. 20 M10x200-10.9 screws are alternately tightened step by step. After completion, zero point calibration A4, A5, A6, T1 testing.

Cleaning and anti-corrosion

The food environment has high requirements for cleanliness. Turn off the controller before cleaning, and if necessary, turn off and lock adjacent devices. Remove the necessary casing and clean the robot with a neutral cleaner. After cleaning, thoroughly remove any residue of the cleaning agent, clean the corroded area, and reapply the anti-corrosion coating. Reinstall safety devices and enclosures. Cleaning agents must not enter electrical or mechanical components, high-pressure cleaners must not be used, and compressed air must not be used to clean bearings and sealing points. After cleaning, test run in T1 mode and observe for any abnormalities.

Common troubleshooting

CBS HO filter blockage: manifested as pressure fluctuations in the balance cylinder, poor breathing, or leakage. Check the color of the filter and replace it if it turns black. Check if the coupling is loose and if the valve cover is sealed.

Gear oil error: Cassida Fluid GL150 must be used for HO type. If the standard ALR 150 is misused, it can lead to food compliance risks and a mismatch in lubrication performance. Confirm the label and oil type when changing the oil. Check the oil level, leaks, and oil quality.

Abnormal balance cylinder pressure: Check the pressure gauge, leakage points, bellows, and clamps. When the pressure is below the allowable range, contact KUKA service and do not inflate it without authorization.

Connector not locked: Check connectors such as X30/XD30, X31/XF31, XF21, X21, etc. The data cable is correctly locked and closed with a buckle, and the motor cable needs to be inserted with 4 fastening screws with a torque of 3.0 Nm.

Zero point loss: replace the motor RDC、 After the encoder battery or collision occurs, it is necessary to recalibrate the zero point. After calibration, test under T1 first, and then gradually restore automatic operation.

Overheating or Overload: Check if the load data is entered correctly, if the tool's center of gravity and inertia exceed the limit, if the ambient temperature is too high, if the gear oil is aging, and if the maintenance cycle is overdue. If the oil temperature exceeds 60 ° C, the maintenance interval should be shortened.

Improper cleaning leads to corrosion: Check the type of cleaning agent and confirm that there is no chlorine or strong acid or alkali. After cleaning, remove any residue and apply a new anti-corrosion layer. Check the seals and surface coatings.

Abnormal security function: All security functions must be tested regularly. Enable the switch to be checked at least once every 12 months. After the safety function or protective device is disabled, it must be immediately restored and functional testing must be conducted.

Stopping distance and safety

The stopping distance and stopping time are related to the load, program multiplier, range of action, and type of shutdown. At 100% operating range, 100% POV, and rated load, the stopping distance of A1 at STOP 0 is about 41.52 ° and the stopping time is about 0.72 s; A2 is about 18.28 ° and 0.46 s; A3 is about 14.86 ° and 0.30 s. The stopping distance and time of A1 at KR 240 R2900-2 HO are about 32.41 ° and 0.66 s; A2 is about 16.20 ° and 0.43 s; A3 is about 17.04 ° and 0.37 s. The stopping distance and time of STOP 1 vary with POV and load, and should refer to the corresponding chart. The actual site should be retested regularly based on load, speed, and brake wear, and it is recommended to check at least once a year.

In terms of safety, KR QUANTEC-2 HO belongs to incomplete machinery and must be integrated into a complete system and meet the EU Machinery Directive before it can be put into operation. The hazardous area consists of both the workspace and the stopping distance. The safety protection device must be located outside the danger zone. Manual mode is divided into T1 and T2. T1 is used for setting, teaching, programming, and program verification, while T2 is only used for testing that requires a speed higher than T1. Automatic mode requires all safety protection devices to function properly, with no one in the hazardous area, or to meet the EN ISO 10218 cooperation requirements. Priority should be given to working outside of hazardous areas during maintenance. If it is necessary to enter, the robot should be turned off and locked with a tag. After the controller is turned 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. The balance cylinder belongs to pressure equipment, and the pressure status must be confirmed before operation and operated by professional personnel.

Overall, the stable operation of KUKA KR QUANTEC-2 HO relies on food grade gear oil, CBS HO filters, balance cylinder pressure checks, and standardized cleaning. On site engineers should incorporate transportation posture, installation base, grounding, oil change volume, torque value, CBS filter spot check, and T1 testing into standard operating procedures to reduce downtime risks, extend robot lifespan, and ensure hygiene compliance and equipment safety in food production environments.