KL 4000 C; KL 4000 C-S

Transcription

1 Linear units KUKA Deutschland GmbH Specification KL 4000 C; KL 4000 C-S Issued: Version: Spez KL 4000 C V3

2 Copyright 2018 KUKA Deutschland GmbH Zugspitzstraße 140 D Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Deutschland GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. KIM-PS5-DOC Translation of the original documentation Publication: Pub Spez KL 4000 C (PDF) en Book structure: Spez KL 4000 C V3.1 Version: Spez KL 4000 C V3 2 / 73 Issued: Version: Spez KL 4000 C V3

3 Contents Contents 1 Introduction Documentation for the linear unit Representation of warnings and notes Purpose Target group Intended use Product description Overview of the linear unit system Description of the linear unit Technical data Basic data Principal dimensions of the KL 4000 C Axis data Foundation loads Plates and labels REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/ Stopping distances and times General information Stopping distances and stopping times, STOP Stopping distances and stopping times, STOP Safety General Liability Intended use EC declaration of conformity, declaration of incorporation and acceptance Terms used Personnel Workspace, safety zone and danger zone Overview of protective equipment Mechanical end stops Mechanical axis limitation (optional) Labeling on the linear unit Safety measures General safety measures Transportation Start-up and recommissioning Manual mode Automatic mode Maintenance and repair Decommissioning, storage and disposal Applied norms and regulations Planning Information for planning Issued: Version: Spez KL 4000 C V3 3 / 73

4 6.2 Machine frame mounting Connecting cables and interfaces Transportation Options Cleaning brushes Removing the cleaning brushes Installing the cleaning brushes Covers Exchanging the track cover Removing the track cover Installing the track cover Permanent lubrication unit Control and signal cable KFL XLUB for "permanent lubrication unit premium "XLUB Maintenance table, permanent lubrication unit Exchanging the permanent lubrication unit Removing the permanent lubrication unit Installing a permanent lubrication unit Exchanging the felt pinion Removing the felt pinion Installing the felt pinion Exchanging the LC cartridge Removing the cartridge Installing the cartridge KUKA Service Requesting support KUKA Customer Support Index / 73 Issued: Version: Spez KL 4000 C V3

5 1 Introduction 1 Introduction 1.1 Documentation for the linear unit The linear unit documentation consists of the following parts: Operating instructions for the linear unit Operating and programming instructions for the KUKA System Software Operating instructions for the robot controller Instructions for options and accessories Parts catalog on storage medium Each of these sets of instructions is a separate document. 1.2 Representation of warnings and notes Safety These warnings are relevant to safety and must be observed. are taken. These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions These warnings mean that death or severe injuries may occur, if no precautions are taken. These warnings mean that minor injuries may occur, if no precautions are taken. These warnings mean that damage to property may occur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: The following procedure must be followed exactly! Procedures marked with this warning must be followed exactly. Notices These notices serve to make your work easier or contain references to further information. Tip to make your work easier or reference to further information. Issued: Version: Spez KL 4000 C V3 5 / 73

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7 2 Purpose 2 Purpose 2.1 Target group This documentation is aimed at users with the following knowledge and skills: Advanced knowledge of mechanical engineering Advanced knowledge of electrical and electronic systems Knowledge of the robot controller system For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at or can be obtained directly from our subsidiaries. 2.2 Intended use Use The linear unit is used for linear traversing of a robot or of other equipment. Use is only permitted under the specified environmental conditions. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. The manufacturer is not liable for any damage resulting from such misuse. The risk lies entirely with the user. Misuse Any use or application deviating from the intended use is deemed to be misuse and is not allowed. This includes e.g.: Use as a climbing aid Operation outside the specified operating parameters Operation without the required safety equipment Changes to the structure of the linear unit, e.g. drill holes can result in damage to the components. This is considered improper use and leads to loss of guarantee and liability entitlements. The linear unit is an integral part of an overall system and may only be operated in a CE-compliant system. Issued: Version: Spez KL 4000 C V3 7 / 73

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9 3 Product description 3 Product description 3.1 Overview of the linear unit system The linear unit is generally integrated into the robot system. Such a system consists of the following components: Linear unit Robot Robot controller KUKA smartpad teach pendant Connecting cables Software Options, accessories Fig. 3-1: Example of a robot system with linear unit 1 Substructure (provided by customer) 4 Connecting cables and ground conductor 2 Linear unit 5 Robot controller 3 Robot 6 KUKA smartpad teach pendant The linear unit can be integrated as an independent product into other systems. Only the linear unit with its connecting cables is considered and described in these instructions. 3.2 Description of the linear unit Overview The linear unit is a single-axis track system and is used principally as an external axis of the robot. The robot is mounted on the carriage, allowing it to be moved along a linear axis. The carriage is moved by its own drive unit. Control is executed by the robot controller. The movement range of the carriage is limited by programmable software limit switches. It is additionally safeguarded by means of mechanical stops (buffers)on the rack side. Issued: Version: Spez KL 4000 C V3 9 / 73

10 Up to four independently driven carriages can be operated on the linear unit. Each of these carriages can additionally be coupled to one or more tender carriages. The tender carriage does not have a drive of its own and is moved by the driven carriage. The rated travel of the carriage is defined specifically for each individual unit. The interval is 500 mm. The linear unit is bolted to a substructure provided by the customer. The energy supply chain contains the supply lines for the robot and the energy and fluid supply. The linear unit consists of the following components: Beam Carriage Drive Energy supply system Covers for tracks (optional) Fig. 3-2: Structure of the linear unit example 1 Substructure 4 Carriage (provided by customer) 2 Beam 5 Energy supply system 3 Drive Installation On the linear unit, the energy supply system can be installed in front of (standard) or behind (mirrored) the beam, as illustrated in (>>> Fig. 3-3 ). In the mirrored design, the beam fastening is not always mirrored. The order-specific layout must be observed. 10 / 73 Issued: Version: Spez KL 4000 C V3

11 3 Product description Fig. 3-3: Installation of linear unit (schematic) 1 Linear unit, mirrored design 2 Linear unit, standard design Beam Carriage The beam is assembled from beam segments 1.5 m and 2 m in length. At the joints, the beam segments are fastened together using centering pins. The length of the beam is dependent on the travel (permitted movement range) of the carriage. The beam is fastened to the customer beam by means of a fastening system. The tracks, racks, stops (buffers) and the mastering notch are fastened to the beam. The tracks can optionally be covered. The robot is fastened to the carriage. For this purpose, the carriage is provided with a mounting face. Two pins are used for centering. The drive unit is seated laterally beneath the carriage. The energy supply system is fastened to the carriage via the driver. The carriage moves on the tracks on four groups of rollers. The range of motion of the carriage is restricted by programmable software limit switches. If the permitted travel is exceeded, stops (buffers) at the end of the beam stop the carriage. There are catch hooks attached to the carriage. If the rollers are damaged, the catch hooks secure the carriage to prevent it from falling. The carriage is mastered at the zero point. A mount for the measuring device is provided for this purpose on the carriage. Detailed information about mastering is contained in the operating and programming instructions for end users or system integrators. Reference holes are provided on the carriage for use by the customer. By means of the reference holes the customer can determine the position of the carriage in relation to the system. Drive The drive assembly consists of a servomotor, a gear unit and fasteners. The pinion on the gear unit engages with the rack on the beam and moves the carriage. The rack and pinion have helical toothing. The motor speed is reduced by the gear unit and transferred by the pinion to the rack. The gear unit is oillubricated. The motor and control cables are connected to the servomotor by means of the connectors. Issued: Version: Spez KL 4000 C V3 11 / 73

12 Energy supply system The energy supply system is required for power supply to and control of the linear unit and the robot. The supply lines for the robot and linear unit and the energy and fluids supply are routed in the energy supply chain. The energy supply chain lies in a side-mounted guide system. It is fastened to the carriage via the driver and thus moves with it. The other end of the energy supply chain is screwed to the fixed point module in the guide system. Figure (>>> Fig. 3-4 ) shows how the driver can be attached to the carriage. The fastening variant depends on the permitted travel (H) of the carriage and on the width of the energy supply chain (BK). Special variants are possible. The connector plate constitutes the interface between the linear unit and the robot controller (connecting cables). All connectors for the supply lines in the energy supply chain are fastened to the connector plate. Fig. 3-4: Attaching the energy supply system 1 Attachment of energy supply system, short travel 2 Attachment of energy supply system, long travel Guide system Electrical installations Options The energy supply chain lies in a guide system. It consists of chain guides, aluminum profiles and add-on parts. It is installed on the side of the linear unit. Special variants are possible. The guide system is fastened to the substructure provided by the customer. The length and width of the guide system depends on the length and width of the energy supply chain. The electrical installations include the motor and control cables for the motor of the linear unit and the motors of the robot. Optionally, the rack and pinion can be lubricated via an automatic lubricating unit (permanent lubrication). The tracks can optionally be fitted with covers. 12 / 73 Issued: Version: Spez KL 4000 C V3

13 4 Technical data 4 Technical data In addition to the standard variant, special models can also be supplied. For this, the order-specific layout must be observed. 4.1 Basic data KL 4000 C, KL 4000 C-S Number of axes 1 Gradation of rated travel 500 mm Repeatability (ISO 9283) Mass of carriage assembly Mass of beam assembly Payload Maximum supplementary load per carriage Maximum supplementary load per tender carriage Beam fastening Foundation loads Foundation dimensions Acceleration in the event of a crash ±0.02 mm m = 516 kg m = 210 kg/m, without mounting base Robot with supplementary loads, see robot 4,000 kg 4,000 kg (KL 4000 C: observe permissible total moved mass of 6,000 kg) (KL 4000 C-S: observe permissible total moved mass of 4,000 kg) See Section (>>> 6.2 "Machine frame mounting" Page 41) See Section (>>> 4.4 "Foundation loads" Page 25) See Section (>>> 6.2 "Machine frame mounting" Page 41) The calculated acceleration in the event of a crash (hitting the buffer) with the smallest mass is about 82 m/s 2. Color Carriage: KUKA orange 2567 Protection rating Sound level Permissible angle of inclination Installation position Number of carriages KL 4000 valid for robots Beam: RAL 7022 Motor and gear unit connected (according to EN 60529): IP65. Linear unit ready for operation, with connecting cables plugged in (according to EN 60529): IP65. < 75 db (A) outside the working envelope (moving KL with moving robot) < 75 db (A) outside the working envelope (moving KL without robot) 0º Ceiling max. 4 carriages KR QUANTEC series, KR FORTEC series Issued: Version: Spez KL 4000 C V3 13 / 73

14 Ambient temperature Operation Storage and transportation 283 K to 328 K (+10 C to +55 C) 233 K to 333 K (-40 C to +60 C) Humidity rating DIN EN Class 3K3 4.2 Principal dimensions of the KL 4000 C Fig. 4-1: Principal dimensions, cross-section Value in brackets apply in the case of an energy supply chain width of BK = 434 mm. * For KR QUANTEC in the standard position (0 ) and mirrored position (180 ) the distance is 650 mm. This value applies in the case of an energy supply chain width of BK = 309 mm. For an energy supply chain width of BK = 434 mm, the distance is 775 mm. 14 / 73 Issued: Version: Spez KL 4000 C V3

15 4 Technical data Fig. 4-2: Principal dimensions 1 Effective travel 2 Effective travel mm (depends on the number of carriages) * The required dimension may also be smaller in certain cases. Issued: Version: Spez KL 4000 C V3 15 / 73

16 Example, principal dimensions Fig. 4-3: Principal dimensions (example) 16 / 73 Issued: Version: Spez KL 4000 C V3

17 4 Technical data Fig. 4-4: Mounting bases, racks, covers (example) Issued: Version: Spez KL 4000 C V3 17 / 73

18 Dimensions of carriage Fig. 4-5: Connection for robot 1 Reference holes Ø12, 4x (measuring device provided by customer) 2 Gauge cartridge, mastering 18 / 73 Issued: Version: Spez KL 4000 C V3

19 4 Technical data 3 Tapped hole M24-38 deep, 16x 4 Dowel pin Ø30 H7 (centering Ø20 H7, fitting length 8 mm, 6x) Adapter plate KR QUANTEC 45º Fig. 4-6: Adapter plate for KR QUANTEC series, 45 position Issued: Version: Spez KL 4000 C V3 19 / 73

20 Adapter plate KR FORTEC 45º Fig. 4-7: Adapter plate for KR FORTEC series, 45 position 20 / 73 Issued: Version: Spez KL 4000 C V3

21 4 Technical data Example, overlength dimension connecting cables Fig. 4-8: Example, overlength dimension for connecting cables, carriage 1 Issued: Version: Spez KL 4000 C V3 21 / 73

22 4.3 Axis data Type KL 4000 C, KL 4000 C-S Axis velocity, axis 1 v max = 1.89 m/s, KL 4000 Effective travel v max = 2.35 m/s, KL 4000 S Min. effective travel = 400 mm Max. effective travel = 30,400 mm (longer rated travels available on request) Direction of travel The direction of travel of the linear unit is the direction in which the carriage moves. A distinction is made between the plus and minus direction. The carriage has a mastering point determined by the mechanical design. The direction of travel is specified in relation to the software zero point E1. The sign indicating the two directions (- and +) is attached at a number of points on the linear unit. If more than one carriage is used on a single linear unit, all the carriages have the same direction of travel. Fig. 4-9: Direction of travel of carriage (schematic) 1 Linear unit, mirrored design 2 Linear unit, standard design Mastering The carriage can be mastered with an EMD mastering set. A mount with a gauge cartridge is provided for this purpose. This is located directly on the carriage. There is a mastering notch on the beam that is used for mastering all carriages. This means that all carriages are in the same axis-specific coordinate system. The mastering position depends on the number of carriages. The mastering arrangement is illustrated schematically in the following diagrams. The illustrations apply to the standard and mirrored versions of the linear unit without a tender carriage. The software zero point (E1) is shifted to 200 mm before the right-hand end of the beam, depending on the number of carriages: 22 / 73 Issued: Version: Spez KL 4000 C V3

23 4 Technical data Number of carriages Software value E1 in mastering position (LW) 1 0 mm (>>> Fig ) mm (>>> Fig ) mm (>>> Fig ) mm (>>> Fig ) If a tender carriage is optionally installed, it is possible that the standard mastering position can no longer be reached on account of the reduced travel range. In this case, the clearance (position of the mastering notch) is increased by at least the travel reduction due to the tender carriage. This is possible in steps of 500 mm. Offset by a multiple of 500 mm. In order to relocate the software zero point to 200 mm before the right-hand end of the beam, the software value E1 in the mastering position must be increased in accordance with this offset. Fig. 4-10: Linear unit with one carriage (LW), mastering position 1 Mastering position at center of carriage 2 Possible travel in plus direction 3 Distance from mastering position to end of track 4 Minimum length of beam In the case of a linear unit with one carriage, the software value E1 in the mastering position is equal to zero. Issued: Version: Spez KL 4000 C V3 23 / 73

24 Fig. 4-11: Linear unit with two carriages (LW), mastering position 1 Mastering position at center of carriage 2 Possible travel in plus direction 3 Distance from mastering position to end of track 4 Minimum length of beam Fig. 4-12: Linear unit with three carriages (LW), mastering position 1 Mastering position at center of carriage 2 Possible travel in plus direction 3 Distance from mastering position to end of track 4 Minimum length of beam 24 / 73 Issued: Version: Spez KL 4000 C V3

25 4 Technical data Fig. 4-13: Linear unit with four carriages (LW), mastering position 1 Mastering position at center of carriage 2 Possible travel in plus direction 3 Distance from mastering position to end of track 4 Minimum length of beam 4.4 Foundation loads Description The foundation loads depend on the robot variant. The specified forces already include the payload and the inertia force (weight) of the robot. These are the maximum values acting on one M30 stud. When a machine frame mounting assembly is used, the effect of the horizontal force F h is shifted to the mounting surface of the substructure. The force F h can act in any horizontal direction. The values specified correspond to the highest generated forces within the corresponding robot family. Issued: Version: Spez KL 4000 C V3 25 / 73

26 Fig. 4-14: Foundation loads 1 Mounting surface of substructure 2 Beam fastening point 3 Mounting base, end 4 Mounting base, center 26 / 73 Issued: Version: Spez KL 4000 C V3

27 4 Technical data Mounting base loads, KR QUANTEC Lateral force F h dynamic (max. load during operation) Lateral force F h dynamic (max. load during E- STOP) Vertical force F V dynamic (pull during operation) Vertical force F V dynamic (pull during E-STOP) Vertical force F V dynamic (pressure during operation) Vertical force F V dynamic (pressure during E- STOP) Mounting base at end of beam N N Mounting base at beam joint N N N N N N N N N N Mounting base loads, KR FORTEC Lateral force F h dynamic (max. load during operation) Lateral force F h dynamic (max. load during E- STOP) Vertical force F V dynamic (pull during operation) Vertical force F V dynamic (pull during E-STOP) Vertical force F V dynamic (pressure during operation) Vertical force F V dynamic (pressure during E- STOP) Mounting base at end of beam N N N N Mounting base at beam joint N N N N N N N N Issued: Version: Spez KL 4000 C V3 27 / 73

28 4.5 Plates and labels The following plates and labels (>>> Fig ) are attached to the linear unit. They must not be removed or rendered illegible. Illegible plates and labels must be replaced. Fig. 4-15: Plates and labels Item 1 2 Description Direction of travel The carriages can be moved in two directions, which are indicated by the plate. Identification plate Content according to Machinery Directive. 28 / 73 Issued: Version: Spez KL 4000 C V3

29 4 Technical data Item 3 Description 4 Hot surface During operation of the linear unit, surface temperatures may be reached that could result in burn injuries. Protective gloves must be worn! High voltage Any improper handling can lead to contact with current-carrying components. Electric shock hazard! 4.6 REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/2006 On the basis of the information provided by our suppliers, this product and its components contain no substances included on the "Candidate List" of Substances of Very High Concern (SVHCs) in a concentration exceeding 0.1 percent by mass. 4.7 Stopping distances and times General information Information concerning the data: The stopping distance is the distance traveled by the carriage from the moment the stop signal is triggered until the carriage comes to a complete standstill. The stopping time is the time that elapses from the moment the stop signal is triggered until the carriage comes to a complete standstill. Stopping distances and stopping times in accordance with DIN EN ISO , Annex B. Stop categories: Stop category 0» STOP 0 Stop category 1» STOP 1 according to IEC The values specified for Stop 0 are guide values determined by means of tests and simulation. They are average values which conform to the requirements of DIN EN ISO The actual stopping distances and stopping times may differ due to internal and external influences on the braking torque. It is therefore advisable to determine the exact stopping distances and stopping times where necessary under the real conditions of the actual robot application. Measuring techniques The stopping distances were measured using the robot-internal measuring technique. Issued: Version: Spez KL 4000 C V3 29 / 73

30 The wear on the brakes varies depending on the operating mode, robot application and the number of STOP 0 stops triggered. It is therefore advisable to check the stopping distance at least once a year Stopping distances and stopping times, STOP 0 The table shows the stopping distances and stopping times after a STOP 0 (category 0 stop) is triggered. These are the maximum values determined for the linear unit with the heaviest robot in a robot series. Stopping distance (mm) Stopping time (s) KR QUANTEC series KR FORTEC series Stopping distances and stopping times, STOP 1 The table shows the stopping distances and stopping times after a STOP 1 (category 1 stop) is triggered. These are the maximum values determined for the linear unit with the heaviest robot in a robot series. Stopping distance (mm) Stopping time (s) KR QUANTEC series KR FORTEC series / 73 Issued: Version: Spez KL 4000 C V3

31 5 Safety 5 Safety 5.1 General In addition to this Safety chapter, the Safety chapter of the operating instructions or assembly instructions of the KUKA robot controller must be observed Liability The linear unit described in this document is a component of an industrial robot. The linear unit is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, misuse of the linear unit may constitute a risk to life and limb or cause damage to it and to other material property. The linear unit may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the linear unit is subject to compliance with this document and with the declaration of incorporation supplied together with the linear unit. Any functional disorders, especially those affecting safety, must be rectified immediately. Safety information Information about safety may not be construed against KUKA Deutschland GmbH. Even if all safety instructions are followed, this is not a guarantee that the linear unit will not cause personal injuries or material damage. No modifications may be carried out to the linear unit without the authorization of KUKA Deutschland GmbH. Additional components, not supplied by KUKA Deutschland GmbH, may be integrated into the linear unit. The user is liable for any damage these components may cause to the linear unit or to other material property. In addition to the Safety chapter, this document contains further safety instructions. These must also be observed Intended use Use Misuse The linear unit is used for linear traversing of a robot or of other equipment. Use is only permitted under the specified environmental conditions. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. The manufacturer is not liable for any damage resulting from such misuse. The risk lies entirely with the user. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. This includes e.g.: Use as a climbing aid Operation outside the specified operating parameters Operation without the required safety equipment Changes to the structure of the linear unit, e.g. drill holes can result in damage to the components. This is considered improper use and leads to loss of guarantee and liability entitlements. Issued: Version: Spez KL 4000 C V3 31 / 73

32 The linear unit is an integral part of an overall system and may only be operated in a CE-compliant system EC declaration of conformity, declaration of incorporation and acceptance The linear unit constitutes partly completed machinery as defined by the EC Machinery Directive. The linear unit may only be put into operation if the following preconditions are met: The linear unit is integrated into a complete system. or: The linear unit, together with other machinery, constitutes a complete system. or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added to the linear unit. The complete system complies with the EC Machinery Directive. This has been confirmed by means of an assessment of conformity. EC declaration of conformity Declaration of incorporation Acceptance The system integrator must issue an EC declaration of conformity for the complete system in accordance with the Machinery Directive. The EC declaration of conformity forms the basis for the CE mark for the system. The linear unit must be operated in accordance with the applicable national laws, regulations and standards. The robot controller has a CE mark in accordance with the EMC Directive and the Low Voltage Directive. The linear unit as partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery is not allowed until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. The declaration of incorporation with its annexes remains with the system integrator as part of the technical documentation of the completed machinery. If no acceptance of the linear unit is performed at the site of installation by KUKA Deutschland GmbH, no responsibility for the linear unit will be accepted by KUKA Deutschland GmbH Terms used Term Axis range Stopping distance Workspace Description Range of each axis, in degrees or millimeters, within which it may move. The axis range must be defined for each axis. Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. The manipulator is allowed to move within its workspace. The workspace is derived from the individual axis ranges. 32 / 73 Issued: Version: Spez KL 4000 C V3

33 5 Safety Term Operator (User) Danger zone Service life KCP KUKA smartpad Manipulator Safety zone Safety options smartpad Stop category 0 Stop category 1 Stop category 2 System integrator (plant integrator) T1 T2 External axis Description The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. The danger zone consists of the workspace and the stopping distances. The service life of a safety-relevant component begins at the time of delivery of the component to the customer. The service life is not affected by whether the component is used in a controller or elsewhere or not, as safety-relevant components are also subject to aging during storage KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. see smartpad The robot arm and the associated electrical installations The safety zone is situated outside the danger zone. Generic term for options which make it possible to configure additional safe monitoring functions in addition to the standard safety functions. Example: SafeOperation Teach pendant for the KR C4 The smartpad has all the operator control and display functions required for operating and programming the industrial robot. The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called STOP 0 in this document. The manipulator and any external axes (optional) perform path-maintaining braking. The drives are deactivated after 1 s and the brakes are applied. Note: This stop category is called STOP 1 in this document. The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a normal braking ramp. Note: This stop category is called STOP 2 in this document. System integrators are people who safely integrate the industrial robot into a complete system and commission it. Test mode, Manual Reduced Velocity (<= 250 mm/s) Test mode, Manual High Velocity (> 250 mm/s permissible) Axis of motion that does not belong to the manipulator, yet is controlled with the same controller. e.g. KUKA linear unit, turn-tilt table, Posiflex 5.2 Personnel The following persons or groups of persons are defined for the linear unit: User Personnel All persons working on the linear unit must have read and understood the linear unit documentation, including the safety chapter. Issued: Version: Spez KL 4000 C V3 33 / 73

34 User Personnel The user must observe the labor laws and regulations. This includes e.g.: The user must comply with his monitoring obligations. The user must carry out briefing at defined intervals. Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. Personnel includes: System integrator Operators, subdivided into: Start-up, maintenance and service personnel Operating personnel Cleaning personnel Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in the operating or assembly instructions for the linear unit and only by personnel specially trained for this purpose. System integrator Operators The linear unit is safely integrated into a complete system by the system integrator. The system integrator is responsible for the following tasks: Installing the linear unit Connecting the linear unit Performing risk assessment Implementing the required safety functions and safeguards Issuing the EC declaration of conformity Attaching the CE mark Creating the operating instructions for the system The operator must meet the following preconditions: The operator must be trained for the work to be carried out. Work on the system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. Work on the electrical and mechanical equipment of the linear unit may only be carried out by specially trained personnel. 5.3 Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards. The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must be safeguarded by means of physical safeguards to prevent danger to persons or the risk of material damage. 34 / 73 Issued: Version: Spez KL 4000 C V3

35 5 Safety The stopping distances must be taken from the documentation for the manipulator and the linear unit, or they must be determined by the system integrator. 5.4 Overview of protective equipment The protective equipment of the linear unit may include: Mechanical end stops Mechanical axis limitation (optional) Labeling of danger areas Not all equipment is relevant for every linear unit Mechanical end stops Mechanical end stops can be installed on the external axes. If the manipulator or an external axis hits an obstruction or a mechanical end stop or mechanical axis limitation, the manipulator and the external axis can no longer be operated safely. They must be taken out of operation and the manufacturer must be consulted before it is put back into operation Mechanical axis limitation (optional) Some linear units can be fitted with adjustable mechanical axis limitation systems. The axis limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system. In the case of linear units that are not designed to be fitted with mechanical axis limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechanical axis limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There must be no shearing or crushing hazards at the loading and transfer areas Labeling on the linear unit All plates, labels, symbols and marks constitute safety-relevant parts of the linear unit. They must not be modified or removed. Labeling on the linear unit: Identification plates Warning labels Safety symbols Designation labels Cable markings Rating plates Issued: Version: Spez KL 4000 C V3 35 / 73

36 5.5 Safety measures General safety measures The linear unit may only be used in perfect technical condition in accordance with its designated use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the linear unit even after the controller has been switched off and locked, e.g. due to incorrect assembly or mechanical defects. The linear unit must therefore be secured by appropriate means. In the absence of operational safety functions and safeguards, the linear unit can cause personal injury or material damage. If safety functions or safeguards are dismantled or deactivated, the linear unit must not be operated. The motors reach temperatures during operation which can cause burns to the skin. Contact must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. Modifications Faults After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes e.g. modifications of the external axes or to the software and configuration settings. The following tasks must be carried out in the case of faults in the linear unit: Switch off the controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. Indicate the fault by means of a label with a corresponding warning (tagout). Keep a record of the faults. Eliminate the fault and carry out a function test Transportation The regulations for transportation must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the linear unit Start-up and recommissioning Before starting up systems and devices for the first time, a check must be carried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested. 36 / 73 Issued: Version: Spez KL 4000 C V3

37 5 Safety If additional components (e.g. cables), which are not part of the scope of supply of KUKA Deutschland GmbH, are integrated into the linear unit, the user is responsible for ensuring that these components do not adversely affect or disable safety functions. Function test The following tests must be carried out before start-up and recommissioning: It must be ensured that: The linear unit is correctly installed and fastened in accordance with the specifications in the documentation. There are no foreign bodies or defective or loose parts on the linear unit. All required safety equipment is correctly installed and operational. The power supply ratings of the linear unit correspond to the local supply voltage and mains type. The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. The connecting cables are correctly connected and the connectors are locked. There is no damage on the linear unit or any other component of the industrial robot that could be attributed to external forces. Example: Dents or abrasion that could be caused by an impact or collision. In the case of such damage, the affected components must be exchanged. In particular, the motor and counterbalancing system must be checked carefully. External forces can cause non-visible damage. For example, it can lead to a gradual loss of drive power from the motor, resulting in unintended movements of the manipulator. Death, injuries or considerable damage to property may otherwise result Manual mode Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes: Jog mode Teaching Programming Program verification The following must be taken into consideration in manual mode: If the drives are not required, they must be switched off to prevent the manipulator or the external axes (optional) from being moved unintentionally. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence. Workpieces, tooling and other objects must not become jammed as a result of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off. All setup work must be carried out, where possible, from outside the safeguarded area. If the setup work has to be carried out inside the safeguarded area, the following must be taken into consideration: Issued: Version: Spez KL 4000 C V3 37 / 73

38 In Manual Reduced Velocity mode (T1): If it can be avoided, there must be no other persons inside the safeguarded area. If it is necessary for there to be several persons inside the safeguarded area, the following must be observed: Each person must have an enabling device. All persons must have an unimpeded view of the industrial robot. Eye-contact between all persons must be possible at all times. The operator must be so positioned that he can see into the danger area and get out of harm s way. In Manual High Velocity mode (T2): This mode may only be used if the application requires a test at a velocity higher than possible in T1 mode. Teaching and programming are not permissible in this operating mode. Before commencing the test, the operator must ensure that the enabling devices are operational. The operator must be positioned outside the danger zone. There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this Automatic mode Automatic mode is only permissible in compliance with the following safety measures: All safety equipment and safeguards are present and operational. There are no persons in the system. The defined working procedures are adhered to. If the manipulator or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered Maintenance and repair After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on the linear unit: Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel. Switch off the controller and secure it (e.g. with a padlock) against being switched on again. If it is necessary to carry out work with the controller switched on, the user must define additional safety measures to ensure the safe protection of personnel. If it is necessary to carry out work with the controller switched on, this may only be done in operating mode T1. 38 / 73 Issued: Version: Spez KL 4000 C V3

39 5 Safety Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work. The EMERGENCY STOP devices must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. Before work is commenced on live parts of the system, the main switch must be turned off and secured against being switched on again. The system must then be checked to ensure that it is deenergized. It is not sufficient, before commencing work on live parts, to execute an EMERGENCY STOP or a safety stop, or to switch off the drives, as this does not disconnect the system from the mains power supply. Parts remain energized. Death or severe injuries may result. Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Deutschland GmbH for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions. Hazardous substances The following safety measures must be carried out when handling hazardous substances: Avoid prolonged and repeated intensive contact with the skin. Avoid breathing in oil spray or vapors. Clean skin and apply skin cream. To ensure safe use of our products, we recommend regularly requesting up-to-date safety data sheets for hazardous substances Decommissioning, storage and disposal The linear unit must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards. 5.6 Applied norms and regulations Name/Edition 2006/42/EU:2006 EN ISO 13850:2015 EN ISO :2015 EN ISO :2012 Definition Machinery Directive: Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast) Safety of machinery: Emergency stop - Principles for design Safety of machinery: Safety-related parts of control systems - Part 1: General principles of design Safety of machinery: Safety-related parts of control systems - Part 2: Validation Issued: Version: Spez KL 4000 C V3 39 / 73

40 EN ISO 12100:2010 EN ISO :2011 EN 614-1:2006+A1:2009 EN :2006/A1:2009 Safety of machinery: General principles of design, risk assessment and risk reduction Industrial robots Safety requirements: Part 1: Robots Note: Content equivalent to ANSI/RIA R , Part 1 Safety of machinery: Ergonomic design principles - Part 1: Terms and general principles Safety of machinery: Electrical equipment of machines - Part 1: General requirements 40 / 73 Issued: Version: Spez KL 4000 C V3

41 6 Planning 6 Planning 6.1 Information for planning In the planning and design phase, care must be taken regarding the functions or applications to be executed by the kinematic system. The following conditions can lead to premature wear. They necessitate shorter maintenance intervals and/or earlier exchange of components. In addition, the permissible operating parameters specified in the technical data must be taken into account and observed during planning. Continuous operation near temperature limits or in abrasive environments Continuous operation close to the performance limits, e.g. high rpm of an axis High duty cycle of individual axes Monotonous motion profiles, e.g. short, frequently recurring axis motions Static axis positions, e.g. continuous asymmetrical stress on the carriage. External forces (process forces) acting on the robot If one or more of these conditions are to apply during operation of the kinematic system, KUKA Deutschland GmbH must be consulted. If the robot reaches its corresponding operation limit or if it is operated near the limit for a period of time, the built-in monitoring functions come into effect and the robot is automatically switched off. This protective function can limit the availability of the robot system. 6.2 Machine frame mounting Description The machine frame mounting assembly is used when the linear unit is fastened to a substructure (e.g. steel structure). It must be ensured that the substructure is able to withstand safely the forces occurring during operation (foundation loads). The following diagram contains all the necessary information that must be observed when preparing the mounting surface. The machine frame mounting assembly (>>> Fig. 6-1 ) consists of: Studs The tapped holes must be created in the substructure in accordance with the layout by the customer before the linear unit has reached the installation site. The responsibility for this lies with the user. Fastening elements Issued: Version: Spez KL 4000 C V3 41 / 73

42 Fig. 6-1: Machine frame mounting 1 Machine frame mounting 2 Substructure 3 Minimum thickness of substructure Bending and torsional stiffness If the linear unit is installed on a substructure, this must have adequate bending and torsional stiffness. An operating load acting on the foundation in any possible direction (see Foundation loads ) must not cause deformations of more than 0.5 mm at any point. 6.3 Connecting cables and interfaces Connecting cables The connecting cables comprise all the cables for transferring energy and signals between the robot controller, the linear unit and the robot. The contents of the connecting cable set (energy supply chain) of the linear unit are determined for each individual order. For operating the linear unit without robot, the connecting cable set contains: Motor cable, linear unit, XM Control cable, linear unit, XP Ground conductor (order as an option) The connecting cables are connected to the robot by means of connectors. The ground conductors are screwed to threaded bolts. The robot motor cable (A1 - A6) and data cable are described in the robot operating instructions. A connector plate serving as an interface is located on the linear unit. The connector plate serves as a common interface for all the connecting cables. Only control cable XP of the linear unit is routed and connected in accordance with the specific order. As a rule, control cable XP runs from the servomotor of the linear unit to the RDC box of the robot. The connecting cables and ground conductors (optional) are connected to the robot controller via the connector plate. A connection panel is provided on the robot controller for motor cable XM of the linear unit. Cable lengths of 7 m, 15 m, 25 m and 35 m are available. A ground conductor is required to provide a low-resistance connection between the linear unit and the control cabinet in accordance with DIN EN The ground conductors are connected via ring cable lugs. A low-resistance connection must be provided between all components of a system. Ground conductor and threaded bolts can be ordered as an option. 42 / 73 Issued: Version: Spez KL 4000 C V3

43 6 Planning Wiring diagrams, connector pin allocations and connector designations for the energy supply chain can be found in the chapter. The following points must be observed when planning and routing the connecting cables: The bending radius for fixed routing 150 mm for motor cables and 60 mm for control cables must not be exceeded. For the connecting cables in the energy supply chain, the bending radius must not exceed 240 mm. Protect cables against exposure to mechanical stress. Route the cables without mechanical stress no tensile forces on the connectors Cables are only to be installed indoors. Observe the permissible temperature range (fixed installation) of 263 K (- 10 C) to 343 K (+70 C). Route the motor cables and the control cables separately in metal ducts; if necessary, additional measures must be taken to ensure electromagnetic compatibility (EMC). The length of the connecting cables between the robot controller and the robot must not exceed 50 m. Interface for energy supply system The linear unit can be fitted with an energy supply system (motor and data cables, hose lines, etc.), which is guided in the energy supply chain. The energy supply chain forms the moving (translational) connection between the connector plate (interface) and the driver on the carriage. Depending on the application, the connector plate differs in design and scope. Detailed information on the connector pin allocation, threaded unions, etc. can be found in separate documentation that is supplied with the system. Issued: Version: Spez KL 4000 C V3 43 / 73

44 44 / 73 Issued: Version: Spez KL 4000 C V3

45 7 Transportation 7 Transportation Description The linear unit must be prepared for transportation. For this, all assemblies and components that are to be transported separately must be dismantled. A maximum of 3 beam segments may be transported together per transport unit. The beam must be prepared for transportation accordingly. If a transport unit includes a carriage, this must be positioned in the middle. It must be ensured that the carriage is secured so that it cannot move. A maximum of two carriages per transport unit are allowed. If the transport device is used, there must be only one carriage on the transport unit. At the joints of the transport units, the tracks result in an overlap. The screws with conical spring washers and covers must be removed at the overlap if necessary. The tracks are not removed at these points. If covers are mounted on the beam segments, these must be removed. For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. Assemblies and components Transportation The following measures are to be taken before assemblies and individual components are transported: Protect components against corrosion. Pack motors and gear units in wooden cases with protection against moisture and transport damage. Wrap components in PE film or VCI paper (RESY symbol), with desiccant if necessary. Provide electrical components with shock-resistant and break-proof packing. Mark transport cases and packing according to the sensitivity of their contents (e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure correct transportation (e.g. indication of center of gravity). In addition to these measures, the regulations and conditions of the company entrusted with the transportation are to be observed. Each transport unit can be transported by fork lift truck or using lifting tackle. Transportation by fork lift truck is only permissible using the transport device. Risk of injury and damage to property resulting from unsuitable handling equipment. Only use handling equipment with a sufficient load-bearing capacity. The beam must always be picked up over the center of gravity. Fork lift truck and transport device The transport unit can be transported in its installation position using a transport device. The device is suitable for two- and three-part transport units with just one carriage. One-part beams cannot be installed in the transport device. They must be attached centrally in order to be able to pick up the beam unit at the center of gravity with the fork lift truck (>>> Fig. 7-1 ). This prevents the beam segment from tilting. The fork lift truck must have a minimum payload capacity of 2.5 t and an adequate fork length. Avoid excessive loading of the fork slots through undue inward or outward movement of hydraulically adjustable forks of the fork lift truck. Failure to do so may result in material damage. Issued: Version: Spez KL 4000 C V3 45 / 73

46 Fig. 7-1: Fork lift truck and transport device Transportation with lifting tackle Each transport unit can also be transported in its installation position using lifting tackle. A minimum payload capacity of 2 t must be observed. If the transport unit consists of the maximum of three beam segments, the ropes must be attached as shown in the illustration (>>> Fig. 7-2 ). All ropes must be long enough to ensure that the linear unit is not damaged and can be transported safely. An angle of 60 between the rope and the linear unit should be observed. If covers are mounted on the beam segments, these must be removed. The beam may tip during transportation. Risk of personal injury and damage to property. If the beam is being transported using lifting tackle, special care must be exercised to prevent it from tipping. Additional safeguarding measures must be taken. It is forbidden to pick up the beam in any other way using a crane! Fig. 7-2: Transportation by crane 46 / 73 Issued: Version: Spez KL 4000 C V3

47 8 Options 8 Options For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. Insufficient fastening of the load or failure of the lifting tackle can cause the load to fall, resulting in injury to persons or material damage: Check that the Load Lifting Attachment is fastened correctly and only use lifting tackle with a sufficient load-bearing capacity. Never work or stand under suspended loads! When work is carried out on the robot system, turn the main switch on the robot controller to OFF and secure it with a padlock to prevent unauthorized persons from switching it on again. During work on the linear unit, there is a risk of slipping or tripping over the beam, tracks and energy supply chain guide. Risk of personal injury and damage to property. Clean the beam before work is started on the linear unit. Do not walk on the tracks, energy supply chain or energy supply chain guide! Carefully step over the energy supply chain and energy supply chain guide! Persons walking on the beam are at risk of falling into the holes. If the linear unit is installed in an elevated position, there is an additional risk of falling from a greater height. Risk of personal injury and damage to property. Do not walk on the beam without the beam covers! If necessary, take measures to guard against falling! The maximum permissible weight of persons is 150 kg. For screwed connections, the fastening screws (standard, strength class 8.8) are to be tightened with the tightening torques specified in the appendix. Tightening torques deviating from these values are specified directly. The specified screw sizes and strength classes are those valid at the copy deadline. The specifications contained in the Parts Catalog are, however, always to be taken as the most up-to-date information. Screws of strength class 10.9 and higher may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. None or false machine data for the linear unit may result in malfunction. Before programming and start-up of the linear unit, the machine data (Translation, Motor-/drive module data, controller setting, $ER- SYSROOT, run-up time and ET1) must be configured and entered correctly. 8.1 Cleaning brushes Description The wipers on the carriage can optionally be fitted with cleaning brushes. Two cleaning brushes are attached to each wiper. They rest on the track and can thus remove any dirt from the range of motion of the rollers. Preconditions Remove the tool and any additional items of equipment if these impede repair work. The carriage is secured against unintended motion. Issued: Version: Spez KL 4000 C V3 47 / 73

48 For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. Unintentional motions of the linear unit, the robot and affected system components can cause injuries and damage to property. If work is carried out on an operational linear unit, the linear unit, the robot and affected system components must be secured by activating the EMERGENCY STOP button. Warn all persons concerned before putting it back into operation Removing the cleaning brushes Procedure 1. Unscrew two M6x Allen screws (>>> Fig. 8-1 ) together with conical spring washers from the wiper to be removed. 2. Remove the wiper from the carriage. 3. Remove the cleaning brushes. To do so, remove the hexagon nuts including conical spring washers from the M6x flat head screws and take off the cleaning brushes. Fig. 8-1: Cleaning brushes 1 Wiper, mirrored 4 Wiper with cleaning brushes (optional) 2 Wiper, standard 5 M6x Allen screw 3 Cleaning brush, top 6 Cleaning brush, side Installing the cleaning brushes Procedure 1. Install new cleaning brushes (>>> Fig. 8-2 ). To do so, fasten each cleaning brush to the wiper with two hexagon nuts including conical spring washers and two M6x flat head screws. Lightly tighten the hexagon nuts so that it is still possible to shift the cleaning brushes easily. 2. Attach the wiper to the carriage. They must be installed in such a way that the upper side of the tracks is always cleaned. 48 / 73 Issued: Version: Spez KL 4000 C V3

49 8 Options 3. Insert two M6x Allen screws with conical spring washers and lightly tighten. 4. Move the cleaning brushes far enough to allow the gap between the wiper and the track to be adjusted. 5. Set a gap of 0.5 mm between the wiper and the track. 6. Check the gap using a feeler gauge plate (0.5 mm). If necessary, set the gap again. 7. Tighten the 2 M6x Allen screws with the specified tightening torque. 8. Press the cleaning brushes lightly against the track and tighten the M6 hexagon nuts with the specified tightening torque. The cleaning brushes must contact the track lightly. Fig. 8-2: Cleaning brushes 1 Wiper, mirrored 4 Wiper with cleaning brushes (optional) 2 Wiper, standard 5 M6x Allen screw 3 Cleaning brush, top 6 Cleaning brush, side 8.2 Covers The linear unit can optionally be fitted with track covers. The covers are attached to the tracks Exchanging the track cover Description The removal and installation of the track cover are described below. Preconditions Remove the tool and any additional items of equipment if these impede repair work. The carriage is secured against unintended motion. For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. Issued: Version: Spez KL 4000 C V3 49 / 73

50 Unintentional motions of the linear unit, the robot and affected system components can cause injuries and damage to property. If work is carried out on an operational linear unit, the linear unit, the robot and affected system components must be secured by activating the EMERGENCY STOP button. Warn all persons concerned before putting it back into operation Removing the track cover Procedure 1. Unscrew Allen screws (>>> Fig. 8-3 )from the track cover. 2. Remove the track cover from the track. 3. Remove the clamping plates from the track cover. 4. Set the track cover down on a suitable support surface. 5. If the track cover is not to be reinstalled, insert the M20x hexagon bolts with conical spring washers into the empty boreholes of the track. Tighten the M20x hexagon screws with the specified tightening torque. 6. Put the track cover and clamping plates into storage if they are not to be reinstalled. Fig. 8-3: Removing the track cover 1 Allen screw 2 Track cover 3 Clamping plate Installing the track cover Procedure 1. Remove the hexagon bolts on the fastening points on the track cover from the track. 2. Insert the clamping plates (>>> Fig. 8-4 ) into the track cover and fasten with the M20x Allen screws. 3. Place the conical spring washers on the track. 4. Move the track cover with the clamping plates into the correct position and carefully place on the track. 5. Insert the M20x Allen screws into the track. 50 / 73 Issued: Version: Spez KL 4000 C V3

51 8 Options 6. Tighten the M20x Allen screws with the specified tightening torque. Fig. 8-4: Installing the track cover 1 Allen screw 2 Track cover 3 Clamping plate 8.3 Permanent lubrication unit The linear unit can be equipped with a comfort or premium permanent lubrication unit. The permanent lubrication unit supplies grease to the pinion and rack. Permanent lubrication unit comfort Permanent lubrication unit premium The permanent lubrication unit comfort consists of an electromechanical drive, a cartridge with 120 cm 3 or 250 cm 3 of lubricant and a battery set. A cartridge with 120 cm 3 (cartridge LC 120) is used as standard for the KL The desired dispensing period and size of the cartridge is set by means of the Set key. The current operating state is displayed with LED signals (red/green) that are visible from all angles as well as on the LCD display. The permanent lubrication unit premium consists of an electromechanical drive, a cartridge with 120 cm 3 or 250 cm 3 of lubricant and a connecting cable for voltage supply. A cartridge with 120 cm 3 (cartridge LC 120) is used as standard for the KL The operating state can be transmitted via the connecting cable to a PLC. The lubrication system dispenses as a function of the operating hours in TIME mode. In IMPULSE mode, a precisely set quantity is dispensed as soon as a voltage is present Control and signal cable KFL XLUB for "permanent lubrication unit premium "XLUB1 Description The control and signal cable is routed in the energy supply chain from the carriage to the connector plate. The control and signal cable has plug-and-socket connections, which enables it to be quickly and reliably exchanged. The plugs and sockets are provided with identification labels. Issued: Version: Spez KL 4000 C V3 51 / 73

52 The length of the connecting cables between the robot controller and the robot must not exceed 50 m. If Safe robots are used, the cable length must not exceed 35 m. Overview Fig. 8-5: Cabling plan and pin allocation diagram 1 Connector plate 3 Carriage 2 Energy supply chain 4 Control and signal cable Wiring diagram Fig. 8-6: Control and signal cable KFL XLUB for "permanent lubrication unit premium " Maintenance table, permanent lubrication unit Description The table provides an overview of the maintenance work (maintenance intervals, activities, lubrication work) and required lubricants. The maintenance intervals given in the table are valid for the operating conditions specified in the technical data. KUKA Deutschland GmbH must be consulted in the case of discrepancies! Only lubricants approved by KUKA Deutschland GmbH may be used. Non-approved lubricants may cause premature wear and failure of assemblies. For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. 52 / 73 Issued: Version: Spez KL 4000 C V3

53 8 Options Unintentional motions of the linear unit, the robot and affected system components can cause injuries and damage to property. If work is carried out on an operational linear unit, the linear unit, the robot and affected system components must be secured by activating the EMERGENCY STOP button. Warn all persons concerned before putting it back into operation. Immediately after the linear unit is switched off, the surface temperature of the motor is liable to be high and could result in burn injuries. Protect body parts that could come into contact with the motor with protective gloves or other suitable protective clothing. Preconditions The maintenance points must be freely accessible. The carriage is secured against unintended motion. Remove the tools and any additional items of equipment if they impede maintenance work. Maintenance symbols Lubricate with brush Check component, visual inspection Fig. 8-7: Maintenance work Interval Item Activity Lubricant 400 h 1 Check the grease on the rack. If necessary, check the permanent lubrication system. Exchange components or adapt the amount of lubricant. 9 months* (max. 12 months) 2 Exchange the cartridge. (>>> "Exchanging the LC cartridge" Page 59) Issued: Version: Spez KL 4000 C V3 53 / 73

54 Interval Item Activity Lubricant 1 year Clean the racks with cleaning solvent and re-grease. 1 year Check the lubrication system for correct operation. Check the state of the felt pinion. Klüberplex AG Art. no *with 3-shift operation In the case of unusual applications or ambient conditions, it may be necessary to adjust the intervals Exchanging the permanent lubrication unit Description The removal and installation of the permanent lubrication unit are described below. Preconditions The carriage is secured against unintended motion. Only lubricants approved by KUKA Deutschland GmbH may be used. Non-approved lubricants may cause premature wear and failure of assemblies. For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. Unintentional motions of the linear unit, the robot and affected system components can cause injuries and damage to property. If work is carried out on an operational linear unit, the linear unit, the robot and affected system components must be secured by activating the EMERGENCY STOP button. Warn all persons concerned before putting it back into operation Removing the permanent lubrication unit Procedure 1. Deactivate the permanent lubrication unit (>>> Fig. 8-8 ) by means of the Set key. For this, press the Set key for 1 second and then release it. The LED signal flashes red. With the permanent lubrication unit premium, it is sufficient to unplug the cable connection from the drive system. 2. Unscrew the Allen screw together with the conical spring washer from the felt pinion holder. 3. Pull the felt pinion holder with the mounted parts off of the roll pin and remove. 4. If the permanent lubrication unit is not to be reinstalled, it must be packaged and put into storage. 54 / 73 Issued: Version: Spez KL 4000 C V3

55 8 Options Fig. 8-8: Removing the permanent lubrication unit 1 Pinion cover 5 Bracket 2 Felt pinion holder 6 Cover 3 Holder 7 Felt pinion 4 Cartridge with drive system Installing a permanent lubrication unit Procedure 1. If necessary, knock out the window in the pinion cover (>>> Fig. 8-9 ). 2. If necessary, tap a new ISO8752-6x10 roll pin into the gear unit. 3. Soak the felt pinion in oil. 4. Fasten the felt pinion holder with the mounted parts to the gear unit. Screw in M8x Allen screw with conical spring washer, but do not tighten. 5. Remove 2 Allen screws together with conical spring washers. Remove the cover and holder. 6. Set the backlash between the pinion and the felt pinion to approximately 1 mm. The backlash can be set by turning the holder. 7. Tighten the M8x Allen screw with the specified tightening torque. 8. Fill with lubricating grease (cartridge with Klüberplex AG11-461, article no ) via the elbow until it emerges from all lubricating channels of the felt pinion. 9. Apply Klüberplex AG to the toothing of the new felt pinion. 10. Fasten the cover and holder to the felt pinion holder with two M6x Allen screws with conical spring washers. Tighten the M6x Allen screws with the specified tightening torque. 11. Insert the battery set into the drive system. Once the permanent lubrication unit has been started, the battery set must not be removed as this will result in a malfunction. 12. Screw the drive system onto the cartridge. 13. Remove the plug and push the cartridge with the drive system through the holder and onto the elbow and screw it in. Issued: Version: Spez KL 4000 C V3 55 / 73

56 14. With the lubrication system premium, attach the cable connection to the drive system. When inserting the connector, turn it until it clearly locks into the coding elements (twist-proof). 15. Set the service time and size of the LC cartridge. With the lubrication system comfort, proceed as follows: Press the Set key for longer than 5 seconds and then release it. The display flashes. Press the Set key twice until the bar appears next to the text LC 120 on the display. This stands for the cartridge size used for this linear unit. Wait 3 seconds until the number for the dispensing time flashes on the display. Press the Set key as many times as necessary until the desired dispensing time is displayed. Wait 3 seconds to leave the settings mode. The settings are displayed. Press the Set key for longer than 1 second in order to switch on the permanent lubrication unit. With the lubrication system premium, proceed as follows in TIME mode: Press the Set key for longer than 5 seconds and release it. TIME and IMPULSE flash on the display. Press the Set key until only TIME flashes on the display. Wait 3 seconds until the three cartridge sizes flash on the display under MODE. Press the Set key twice until the bar appears next to the text LC 120 on the display. This stands for the cartridge size used for this linear unit. Wait 3 seconds to switch from MODE to TIME. Press the Set key as many times as necessary until the desired dispensing time is displayed. Wait 3 seconds to leave the settings mode. The settings are displayed. Press the Set key for longer than 1 second in order to switch on the permanent lubrication unit. With the lubrication system premium, proceed as follows in IMPULSE mode: Press the Set key for longer than 5 seconds and then release it. TIME and IMPULSE flash on the display. Press the Set key until only IMPULSE flashes on the display. Wait 3 seconds until the three cartridge sizes flash on the display under MODE. Press the Set key twice until the bar appears next to the text LC 120 on the display. This stands for the cartridge size used for this linear unit. Wait 3 seconds to switch from MODE to TIME. Press the Set key as many times as necessary until the desired dispensing time is displayed. Wait 3 seconds to leave the settings mode. The settings are displayed. Press the Set key for longer than 1 second in order to switch on the permanent lubrication unit. 56 / 73 Issued: Version: Spez KL 4000 C V3

57 8 Options Fig. 8-9: Installing the permanent lubrication unit 1 Pinion cover 5 Bracket 2 Felt pinion holder 6 Cover 3 Holder 7 Felt pinion 4 Cartridge with drive system Exchanging the felt pinion Description The removal and installation of the felt pinion are described below. Preconditions The carriage is secured against unintended motion. Only lubricants approved by KUKA Deutschland GmbH may be used. Non-approved lubricants may cause premature wear and failure of assemblies. For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. Unintentional motions of the linear unit, the robot and affected system components can cause injuries and damage to property. If work is carried out on an operational linear unit, the linear unit, the robot and affected system components must be secured by activating the EMERGENCY STOP button. Warn all persons concerned before putting it back into operation Removing the felt pinion Procedure 1. Deactivate the permanent lubrication unit by means of the Set key. For this, press the Set key for 1 second and then release it. The LED signal flashes red. With the permanent lubrication unit premium, it is sufficient to unplug the cable connection from the drive system. Issued: Version: Spez KL 4000 C V3 57 / 73

58 2. Unscrew the cartridge with the drive system (>>> Fig ) from the elbow and pull them through the holder. 3. Fit the plug on the cartridge. 4. Unscrew the Allen screw together with the conical spring washer from the felt pinion holder. 5. Pull the felt pinion holder with the mounted parts off the roll pin and remove. 6. Unscrew two Allen screws together with conical spring washers. Remove the cover and holder. 7. Unscrew the M6x flat head screw from the mounting shaft. 8. Pull the clamping disk and felt pinion off the mounting shaft. 9. Dispose of the felt pinion in accordance with the pertinent regulations. Fig. 8-10: Removing the felt pinion 1 Pinion cover 5 Elbow 2 Felt pinion holder 6 Cover 3 Holder 7 Felt pinion 4 Cartridge with drive system Installing the felt pinion Procedure 1. Soak the felt pinion (>>> Fig ) in oil. 2. Push the disk and new felt pinion onto the mounting shaft. 3. Place the clamping disk on the felt pinion and insert an M6x flat head screw into the mounting shaft. Tighten the M6x flat head screw with the specified tightening torque. 4. Fasten the felt pinion holder with the mounted parts to the gear unit. Screw in M8x Allen screw with conical spring washer, but do not tighten. 5. Set the backlash between the pinion and the felt pinion to approximately 1 mm. The backlash can be set by turning the holder. 6. Tighten the M8x Allen screw with the specified tightening torque. 58 / 73 Issued: Version: Spez KL 4000 C V3

59 8 Options 7. Fill with lubricating grease (cartridge with Klüberplex AG11-461, article no ) via the elbow until it emerges from all lubricating channels of the felt pinion. 8. Fasten the cover and holder to the felt pinion holder with 2 M6x Allen screws with conical spring washers. Tighten the M6x Allen screws with the specified tightening torque. 9. Remove the plug and push the cartridge with the drive system through the holder and onto the elbow and screw it in. 10. With the lubrication system premium, attach the cable connection to the drive system. When inserting the connector, turn it until it clearly locks into the coding elements (twist-proof). 11. Press the Set key for longer than 1 second in order to switch on the permanent lubrication unit. Fig. 8-11: Installing the felt pinion 1 Pinion cover 5 Bracket 2 Felt pinion holder 6 Cover 3 Holder 7 Felt pinion 4 Cartridge with drive system Exchanging the LC cartridge Description The removal and installation of the LC cartridge are described below. If a battery set was used, this must be exchanged as well. Once the permanent lubrication unit has been started, the battery set must not be removed as this will result in a malfunction. Preconditions The carriage is secured against unintended motion. Only lubricants approved by KUKA Deutschland GmbH may be used. Non-approved lubricants may cause premature wear and failure of assemblies. Issued: Version: Spez KL 4000 C V3 59 / 73

60 For work on the linear unit, the use of personal protective equipment is mandatory. Where applicable, additional local or national accident prevention regulations must also be observed. Unintentional motions of the linear unit, the robot and affected system components can cause injuries and damage to property. If work is carried out on an operational linear unit, the linear unit, the robot and affected system components must be secured by activating the EMERGENCY STOP button. Warn all persons concerned before putting it back into operation Removing the cartridge Procedure 1. Deactivate the permanent lubrication unit by means of the Set key. For this, press the Set key for 1 second and then release it. The LED signal flashes red. With the permanent lubrication unit premium, it is sufficient to unplug the cable connection from the drive system. 2. Unscrew the cartridge with the drive system (>>> Fig ) from the bracket and pull them through the holder. 3. Unscrew the drive system from the cartridge and dispose of it. 4. With the lubrication system comfort, remove the battery set from the drive system. Fig. 8-12: Removing the cartridge 1 Drive system 3 Holder 2 Cartridge 4 Bracket Installing the cartridge Procedure 1. With the lubrication system comfort, insert a new battery set into the drive system (>>> Fig ). Once the permanent lubrication unit has been started, the battery set must not be removed as this will result in a malfunction. 2. Screw the drive system onto the cartridge. 3. Remove the plug and push the cartridge with the drive system through the holder and onto the elbow and screw it in. 4. With the lubrication system premium, attach the cable connection to the drive system. When inserting the connector, turn it until it clearly locks into the coding elements (twist-proof). 60 / 73 Issued: Version: Spez KL 4000 C V3

61 8 Options 5. If necessary, reset the service time and size of the cartridge. See also Section (>>> "Installing a permanent lubrication unit" Page 55). Fig. 8-13: Installing the cartridge 1 Drive system 3 Holder 2 Cartridge 4 Bracket Issued: Version: Spez KL 4000 C V3 61 / 73