KUKA KR SCARA-2 CS Assembly, Debugging, and Operation Guide

AIR1-AIR4: Pneumatic interface, corresponding to Ø 4mm and Ø 6mm trachea respectively.

Interface A2 (Arm): The standard version includes motor indicator lights, brake release buttons (for shaft 3 and shaft 4), as well as X94 (8-pin M12 Ethernet) and X41 (15 pin D-sub) user interfaces.

For version C01, interface A1 has removed the pneumatic interface and user interface, retaining only the battery, X30, and X31. This means that in version C01, all pneumatic and user I/O connections need to be made through interface A2 on the arm. This design reduces the cable density at the back of the base, making it easier to route cables in narrow spaces.

3. Cable wiring specifications

Bending radius: When fixing and laying motor cables, the minimum bending radius shall not be less than 55mm; for data cables, it shall not be less than 45mm.

Electromagnetic compatibility: Motor cables and data cables must be separately laid in their respective metal cable trays to prevent electromagnetic interference.

Reserved space: It is recommended to reserve at least 200mm of space behind interface A1 for connecting cables.

Core maintenance: Zero point calibration and battery replacement

The absolute accuracy of SCARA robots depends on the zero position of each axis. After replacing the motor, reducer, cable, or battery, the zero point may shift and must be recalibrated.

1. Zero point calibration (Mastering)

Calibration of A1 and A2 axes requires specialized calibration tools (Article number: 0000-396-617). The steps are as follows:

Insert the calibration tool into the calibration slots of A1 and A2 axes.

Gently move the robot to align the two calibration slots and fully embed the calibration tool.

In the calibration page of KUKA. ControlStudio or smartPAD touch, select "Set Current" to set the zero point.

Remove the calibration tool and test the program in T1 mode.

2. Battery replacement

The KR SCARA-2 CS series is equipped with a backup battery inside the base for storing encoder data in the event of a power outage. According to the maintenance schedule, the battery unit needs to be replaced once a year. If the battery is depleted, the zero point data will be lost and a new zero point calibration must be performed. Therefore, it is recommended to include battery replacement in the annual preventive maintenance plan.

Manual movement and brake release operation

In debugging or emergency situations, it may be necessary to manually move the robot. KR SCARA-2 CS offers two ways:

Servo Free mode: activated through KUKA. ControlStudio. In this mode, the brake of axis 1 and axis 2 can be released through software.

Brake release button: located on the arm (interface A2). Press and hold this button to release the brake of shaft 3 and shaft 4.

Safety warning: When the brake release button is pressed, axis 3 (Z-axis) may fall freely due to the weight of the load. When operating, it is necessary to hold the load or tool with your hands to prevent falling and causing personal injury or equipment damage. In addition, when manually moving axis 1 and axis 2, it is also important to note that the robot may experience unexpected movements due to gravity or inertia.

Stopping distance and time: core data for safety design

When planning safety fences and assessing risks, stopping distance and stopping time are key parameters. According to DIN EN ISO 10218-1 standard, stopping distance=reaction distance+braking distance.

KUKA provides two types of stop category data:

Stop 0 (Category 0): The driver immediately loses power, and the short-circuit brake and electromechanical brake engage simultaneously. Usually triggered by robot power outage, CPU failure, or fatal drive system failure.

Stop 1 (Category 1): The robot is controlled to stop along the original path, and then the drive is powered off and the brake is applied. Usually triggered by emergency stop, safety input, or control failure.

Taking KR 6 R500 Z200-2 CS as an example, under 100% project and rated load:

Stop 0: Axis 1 stops at a distance of approximately 46.42 ° with a stop time of 0.21s; Axis 3 stops at a distance of 58.47mm with a stop time of 0.08s.

Stop 1: Axis 1 stops at a distance of approximately 46.56 ° with a stop time of 0.17s; Axis 3 stops at a distance of 85.07mm with a stop time of 0.12s.

Engineering suggestion: The actual stopping distance may vary due to load, speed, and wear. It is recommended to check the stopping distance at least once a year, especially in high load or high-frequency Stop 0 shutdown applications. The design of safety fences must be based on the worst-case stopping distance and combined with personnel response time to ensure sufficient safety clearance.

Scrap and Disposal: Environmental Protection and Compliance

When the robot reaches the end of its service life, it must be disassembled and recycled according to the material type. The main material composition of KR SCARA-2 CS includes:

Metal: cast aluminum (base, arm, connecting rod), copper (cable), steel (gearbox, ball screw, screw).

Plastic: ABS, PC (cover plate), NBR (O-ring), PU (hose), PUR (cable sheath).

Electronic components such as EDS and motors need to be treated as electronic waste and do not require further disassembly.