KR 360-3; KR 500-3 - KUKA Robotics

RobotsKUKA Roboter GmbHKR 360-3; KR 500-3SpecificationIssued: 22.07.2013Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

KR 360-3; KR 500-3© Copyright 2013KUKA Roboter GmbHZugspitzstraße 140D-86165 AugsburgGermanyThis documentation or excerpts therefrom may not be reproduced or disclosed to third parties withoutthe express permission of KUKA Roboter GmbH.Other functions not described in this documentation may be operable in the controller. The user hasno 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 softwaredescribed. Nevertheless, discrepancies cannot be precluded, for which reason we are not able toguarantee 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.Translation of the original documentationKIM-PS5-DOCPublication:Pub Spez KR 360-3 KR 500-3 (PDF) enBook structure: Spez KR 360-3 KR 500-3 V4.1Version:Spez KR 360-3 KR 500-3 V5 en (PDF)2 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

ContentsContents1 Introduction .................................................................................................. 51.1 Industrial robot documentation ................................................................................... 51.2 Representation of warnings and notes ...................................................................... 51.3 Terms used ................................................................................................................ 62 Purpose ........................................................................................................ 72.1 Target group .............................................................................................................. 72.2 Intended use .............................................................................................................. 73 Product description ..................................................................................... 93.1 Overview of the robot system .................................................................................... 93.2 Description of the robot .............................................................................................. 94 Technical data .............................................................................................. 134.1 Basic data .................................................................................................................. 134.2 Axis data .................................................................................................................... 164.3 Payloads .................................................................................................................... 234.4 Foundation data ......................................................................................................... 334.5 Plates and labels ........................................................................................................ 364.6 Stopping distances and times .................................................................................... 384.6.1 General information .............................................................................................. 384.6.2 Terms used ........................................................................................................... 384.6.3 Stopping distances and times, KR 360-3; KR 360-3 F ......................................... 394.6.3.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 394.6.3.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 404.6.3.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 424.6.3.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 444.6.4 Stopping distances and times, KR 360 L240-3, KR 360 L240-3 F ....................... 444.6.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 444.6.4.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 454.6.4.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 474.6.4.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 494.6.5 Stopping distances and times, KR 360 L280-3, KR 360 L280-3 F ....................... 494.6.5.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 494.6.5.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 504.6.5.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 524.6.5.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 544.6.6 Stopping distances and times, KR 500-3, KR 500-3 F, KR 500-3 C .................... 544.6.6.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 544.6.6.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 554.6.6.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 574.6.6.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 594.6.7 Stopping distances and times, KR 500 L340-3, KR 500 L340-3 F ....................... 594.6.7.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 594.6.7.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 604.6.7.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 624.6.7.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 644.6.8 Stopping distances and times, KR 500 L420-3, KR 500 L420-3 F, KR 500 L420-3 C 64Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)3 / 109

KR 360-3; KR 500-34.6.8.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 644.6.8.2 Stopping distances and stopping times for STOP 1, axis 1 ............................ 654.6.8.3 Stopping distances and stopping times for STOP 1, axis 2 ............................ 674.6.8.4 Stopping distances and stopping times for STOP 1, axis 3 ............................ 695 Safety ............................................................................................................ 715.1 General ...................................................................................................................... 715.1.1 Liability ................................................................................................................. 715.1.2 Intended use of the industrial robot ...................................................................... 725.1.3 EC declaration of conformity and declaration of incorporation ............................. 725.1.4 Terms used .......................................................................................................... 735.2 Personnel .................................................................................................................. 745.3 Workspace, safety zone and danger zone ................................................................ 755.4 Overview of protective equipment ............................................................................. 765.4.1 Mechanical end stops ........................................................................................... 765.4.2 Mechanical axis range limitation (optional) ........................................................... 765.4.3 Axis range monitoring (optional) ........................................................................... 775.4.4 Options for moving the manipulator without drive energy .................................... 775.4.5 Labeling on the industrial robot ............................................................................ 785.5 Safety measures ........................................................................................................ 785.5.1 General safety measures ..................................................................................... 785.5.2 Transportation ...................................................................................................... 795.5.3 Start-up and recommissioning .............................................................................. 805.5.4 Manual mode ........................................................................................................ 815.5.5 Automatic mode ................................................................................................... 815.5.6 Maintenance and repair ........................................................................................ 825.5.7 Decommissioning, storage and disposal .............................................................. 835.6 Applied norms and regulations .................................................................................. 836 Planning ........................................................................................................ 856.1 Mounting base 175 mm ............................................................................................. 856.2 Mounting base 200 mm ............................................................................................. 876.3 Machine frame mounting ........................................................................................... 896.4 Connecting cables and interfaces ............................................................................. 907 Transportation ............................................................................................. 937.1 Transporting the robot ............................................................................................... 938 KUKA Service ............................................................................................... 978.1 Requesting support ................................................................................................... 978.2 KUKA Customer Support ........................................................................................... 97Index ............................................................................................................. 1054 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

1 Introduction1 Introduction1.1 Industrial robot documentationThe industrial robot documentation consists of the following parts:• Documentation for the manipulator• Documentation for the robot controller• Operating and programming instructions for the KUKA System Software• Documentation relating to options and accessories• Parts catalog on storage mediumEach of these sets of instructions is a separate document.1.2 Representation of warnings and notesSafetyThese warnings are relevant to safety and must be observed.are taken.These warnings mean that it is certain or highly probablethat death or severe injuries will occur, if no precautionsThese warnings mean that death or severe injuries mayoccur, if no precautions are taken.These warnings mean that minor injuries may occur, ifno 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 orgeneral safety measures.These warnings do not refer to individual hazards or individual precautionarymeasures.This warning draws attention to procedures which serve to prevent or remedyemergencies or malfunctions:Procedures marked with this warning must be followedexactly.NotesThese hints serve to make your work easier or contain references to furtherinformation.Tip to make your work easier or reference to further information.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)5 / 109

KR 360-3; KR 500-31.3 Terms usedTermStopping distanceKCPManipulatorDescriptionStopping distance = reaction distance + braking distanceThe stopping distance is part of the danger zone.The KCP (KUKA Control Panel) teach pendant has all the operator controland display functions required for operating and programming theindustrial robot.The KCP variant for the KR C4 is called KUKA smartPAD. The generalterm “KCP”, however, is generally used in this documentation.The robot arm and the associated electrical installations6 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

2 Purpose2 Purpose2.1 Target groupThis 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 systemFor optimal use of our products, we recommend that our customerstake part in a course of training at KUKA College. Information aboutthe training program can be found at www.kuka.com or can be obtaineddirectly from our subsidiaries.2.2 Intended useUseMisuseThe industrial robot is intended for handling tools and fixtures, or for processingor transferring components or products. Use is only permitted under thespecified environmental conditions.Any use or application deviating from the intended use is deemed to be impermissiblemisuse. This includes e.g.:• Transportation of persons and animals• Use as a climbing aid• Operation outside the permissible operating parameters• Use in potentially explosive environments• Use in underground miningChanging the structure of the manipulator, e.g. by drillingholes, etc., can result in damage to the components. Thisis considered improper use and leads to loss of guarantee and liability entitlements.The robot system is an integral part of a complete system and mayonly be operated in a CE-compliant system.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)7 / 109

KR 360-3; KR 500-38 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

3 Product description3 Product description3.1 Overview of the robot systemThe robot system consists of the following components:• Robot• Robot controller• smartPAD teach pendant• Connecting cables• Software• Options, accessoriesFig. 3-1: Example of a robot system1 Robot 3 Robot controller2 Connecting cables 4 smartPADteach pendant3.2 Description of the robotOverviewThe robot is designed as a 6-axis jointed-arm kinematic system. The structuralcomponents of the robot are made of light alloy and iron castings. The axesare driven by AC servomotors. A hydropneumatic counterbalancing system isused to equalize the load moment about axis 2.The robot consists of the following principal components:• In-line wrist• Arm• Link arm• Rotating column• Base frame• Counterbalancing system• Electrical installationsIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)9 / 109

KR 360-3; KR 500-3Fig. 3-2: Principal components1 Arm 5 Counterbalancing system2 Electrical installations 6 In-line wrist3 Rotating column 7 Link arm4 Base frameIn-line wristArmThe robot is fitted with a 3-axis in-line wrist for a rated payload of 500 kg. Thein-line wrist comprises axes 4, 5 and 6. It is driven by three AC servomotorsinstalled at the rear end of the arm via drive shafts. The motor unit consists ofbrushless AC servomotors with a permanent-magnet single-disk brake andhollow-shaft resolver, both integrated. The permanent-magnet single-diskbrakes perform a holding function when the servomotor is at rest and contributeto the braking of the respective axis in the event of short-circuit braking(e.g. if one or more of the enabling switches is released while in Test mode).Short-circuit braking must not be used to stop the robot under normal circumstances.The gear units of the in-line wrist are supplied with oil from two separateoil chambers.If the permissible turning range of a wrist axis is exceeded, the robot isswitched off by means of software limit switches. The turning range of A5 ismechanically limited by end stops performing a buffer function.The in-line wrist forms an exchangeable unit with a standardized mechanicalinterface to the arm.The assembly also has a gauge mount with a gauge cartridge, through whichthe mechanical zero of the axis can be determined by means of an electronicprobe (accessory) and transferred to the controller.The in-line wrist variant “F” is available for operating conditions involving greatermechanical and thermal stress.The arm is the link between the in-line wrist and the link arm. It houses the motorsof the wrist axes A4, A5 and A6, as well as motor A3. The arm is drivenby an AC servomotor via a gear unit that is installed between the arm and thelink arm. The maximum permissible swivel range is limited by mechanical limit10 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

3 Product descriptionstops with a buffer function in the positive and negative directions in additionto the software limit switches.The arm variant “F” is available for operating conditions involving greater mechanicaland thermal stress. The arms of the F variants are pressurized to preventpenetration of moisture and dust.Link armRotating columnBase frameCounterbalancingsystemElectrical installationsOptionsThe link arm is the assembly located between the arm and the rotating column.It is mounted on one side of the rotating column via a gear unit. The motor unitconsists of a brushless AC servomotor with a permanent-magnet single-diskbrake and hollow-shaft resolver, both integrated. The permanent-magnet single-diskbrake performs a holding function when the servomotor is at rest andcontributes to the braking of the respective axis in the event of short-circuitbraking (e.g. if one or more of the enabling switches is released while in Testmode). Short-circuit braking must not be used to stop the robot under normalcircumstances. During motion about axis 2, the link arm moves about the stationaryrotating column. The usable software swivel range is limited by mechanicallimit stops with a buffer function in the positive and negative directionsin addition to the software limit switches.The rotating column houses the motors of axes 1 and 2. The rotational motionof axis 1 is performed by the rotating column. It is screwed to the base framevia the gear unit of axis 1. Inside the rotating column is a brushless AC servomotorwith a permanent-magnet single-disk brake and hollow-shaft resolver,both integrated, for driving axis 1. The permanent-magnet single-disk brakeperforms a holding function when the servomotor is at rest and contributes tothe braking of the respective axis in the event of short-circuit braking (e.g. ifone or more of the enabling switches is released while in Test mode). Shortcircuitbraking must not be used to stop the robot under normal circumstances.The counterbearing for the counterbalancing system is integrated into the rearof the rotating column housing.The base frame is the base of the robot. It is screwed to the mounting base.The interfaces for the electrical installations and the energy supply systems(accessory) are housed in the base frame. The base frame and rotating columnare connected via the gear unit of axis 1. The flexible tube for the electricalinstallations and the energy supply system is accommodated in the baseframe.The counterbalancing system is an assembly installed between the rotatingcolumn and the link arm. This assembly minimizes the torques generatedabout axis 2 when the robot is moving or stationary. A closed, hydropneumaticsystem is used. The system consists of two accumulators, a hydraulic cylinderwith associated hoses, a pressure gauge and a bursting disc as a safety elementto protect against overload. The accumulators correspond to categoryIII, fluid group 2, of the Pressure Equipment Directive. Different variants ofthe counterbalancing system are used for floor and ceiling-mounted robotsand for the F variants. The mode of operation is reversed for ceiling-mountedrobots, i.e. the piston rod pushes against the link arm.The electrical installations are described in Chapter .The robot can be fitted and operated with various options, e.g. working rangelimitation. The options are described in separate documentation.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)11 / 109

KR 360-3; KR 500-312 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4 Technical data4.1 Basic dataBasic dataKR 360-3Type KR 360-3KR 360-3 FKR 360 L240-3KR 360 L240-3 FKR 360 L280-3KR 360 L280-3 FNumber of axes 6Volume of working KR 360-3: 68 m 3envelopeKR 360-3 F: 68 m 3KR 360 L240-3: 114.5 m 3KR 360 L240-3 F: 114.5 m 3KR 360 L280-3: 88 m 3Pose repeatability(ISO 9283)Working envelope referencepointWeightPrincipal dynamicloadsProtection classificationof the robotProtection classificationof the in-line wristProtection classificationof the “F” in-linewristSound levelMounting positionSurface finish, paintworkKR 360 L280-3 F: 88 m 3±0.08 mmIntersection of axes 4 and 5KR 360-3: 2,375 kgKR 360-3 F: 2,375 kgKR 360 L240-3: 2,411 kgKR 360 L240-3 F: 2,411 kgKR 360 L280-3: 2,405 kgKR 360 L280-3 F: 2,405 kgSee Loads acting on the foundationIP 65ready for operation, with connecting cablesplugged in (according to EN 60529)IP 65IP 67< 75 dB (A) outside the working envelopeFloorPermissible angle of inclination ≤ 10ºBase (stationary): black (RAL 9005); movingparts: KUKA orange 2567Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)13 / 109

KR 360-3; KR 500-3Basic dataKR 500-3Type KR 500-3KR 500-3 FKR 500-3 CKR 500 L340-3KR 500 L340-3 FKR 500 L420-3KR 500 L420-3 FKR 500 L420-3 CNumber of axes 6Volume of working KR 500-3: 68 m 3envelopeKR 500-3 F: 68 m 3KR 500-3 C: 68 m 3KR 500 L340-3: 114.5 m 3KR 500 L340-3 F: 114.5 m 3KR 500 L420-3: 88 m 3KR 500 L420-3 F: 88 m 3Pose repeatability(ISO 9283)Work envelope referencepointWeightPrincipal dynamicloadsProtection classificationof the robotProtection classificationof the in-line wristProtection classificationof the in-line wristFSound levelKR 500 L420-3 C: 88 m 3±0.08 mmIntersection of axes 4 and 5KR 500-3: 2,375 kgKR 500-3 F: 2,375 kgKR 500-3 C: 2,375 kgKR 500 L340-3: 2,411 kgKR 500 L340-3 F: 2,411 kgKR 500 L420-3: 2,405 kgKR 500 L420-3 F: 2,405 kgKR 500 L420-3 C: 2,405 kgSee Loads acting on the foundationIP 65ready for operation, with connecting cablesplugged in (according to EN 60529)IP 65IP 67< 75 dB (A) outside the working envelope14 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataMounting positionSurface finish, paintworkFloorPermissible angle of inclination ≤ 10ºCeilingNo angle of inclination permissibleBase (stationary): black (RAL 9005); movingparts: KUKA orange 2567Foundry robotsOverpressure in thearmCompressed airCompressed air supplyline0.01 MPa (0.1 bar)Free of oil and waterAir line in the cable setAir consumption 0.1 m 3 /hAir line connectionPressure regulatorconnectionInput pressurePressure regulatorManometer rangeFilter gauge 25 - 30 µmThermalloadingResistanceSpecial paint finish onwristSpecial paint finish onthe robotOther ambient conditionsQuick Star push-in fitting for hose PUN-6x1, blueR 1/8", internal thread0.1 - 1.2 MPa (1 - 12 bar)0.005 - 0.07 MPa (0.05 - 0.7 bar)0.0 - 0.1 MPa (0.0 - 1.0 bar)10 s/min at 353 K (180 °C)Increased resistance to dust, lubricants, coolantsand water vapor.Heat-resistant and heat-reflecting silver paint finishon the in-line wrist.Special paint finish on the entire robot, and anadditional protective clear coat.KUKA Roboter GmbH must be consulted if therobot is to be used under other ambient conditions.Ambient temperatureConnectingcablesOperation +10 °C to +55 °C (283 K to 328 K)Storage and transportation-40 °C to +60 °C (233 K to 333 K)Start-up +10 °C to +15 °C (283 K to 288 K)At these temperatures the robot may have to bewarmed up before normal operation.Ambient conditions DIN EN 60721-3-3Class 3K3Cable designation Connector designation Interface with robotMotor cable X20.1 - X30.1 Harting connectors atboth endsMotor cable X20.4 - X30.4 Harting connectors atboth endsControl cable X21 - X31 HAN 3A EMC at bothendsGround conductor /equipotential bonding16 mm 2 (optional)M8 ring cable lug atboth endsIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)15 / 109

KR 360-3; KR 500-3Cable lengthsStandard7 m, 15 m, 25 m, 35 m, 50 mFor detailed specifications of the connecting cables, see .4.2 Axis dataAxis dataKR 360-3The following axis data are valid for the robots:• KR 360-3• KR 360-3 FAxisThe following axis data are valid for the robots:• KR 360 L240-3• KR 360 L240-3 FThe following axis data are valid for the robots:• KR 360 L280-3• KR 360 L280-3 FRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 98 °/s2 +20° to -130° 91 °/s3 +144° to -100° 89 °/s4 +/-350° 110 °/s5 +/-120° 111 °/s6 +/-350° 153 °/sAxisRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 98 °/s2 +20° to -130° 91 °/s3 +144° to -100° 89 °/s4 +/-350° 110 °/s5 +/-120° 111 °/s6 +/-350° 153 °/sAxisRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 98 °/s2 +20° to -130° 91 °/s3 +144° to -100° 89 °/s4 +/-350° 110 °/s5 +/-120° 111 °/s6 +/-350° 153 °/sAxis dataKR 500-3The following axis data are valid for the robots:• KR 500-3• KR 500-3 FAxisRange of motion, softwarelimited1 +/-185° 84 °/s2 +20° to -130° 79 °/sSpeed withrated payload16 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataAxis3 +144° to -100° 73 °/s4 +/-350° 76 °/s5 +/-120° 74 °/s6 +/-350° 123 °/sThe following axis data are valid for the robot:• KR 500-3 CAxisThe following axis data are valid for the robots:• KR 500 L340-3• KR 500 L340-3 FThe following axis data are valid for the robots:• KR 500 L420-3• KR 500 L420-3 FThe following axis data are valid for the robot:• KR 500 L420-3 CRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 84 °/s2 +20° to -130° 79 °/s3 +144° to -100° 73 °/s4 +/-350° 76 °/s5 +/-118° 74 °/s6 +/-350° 123 °/sAxisRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 84 °/s2 +20° to -130° 79 °/s3 +144° to -100° 73 °/s4 +/-350° 76 °/s5 +/-120° 74 °/s6 +/-350° 123 °/sAxisRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 84 °/s2 +20° to -130° 79 °/s3 +144° to -100° 73 °/s4 +/-350° 76 °/s5 +/-120° 74 °/s6 +/-350° 123 °/sAxisRange of motion, softwarelimitedRange of motion, softwarelimited1 +/-185° 84 °/s2 +20° to -130° 79 °/s3 +144° to -100° 73 °/s4 +/-350° 76 °/sSpeed withrated payloadSpeed withrated payloadIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)17 / 109

KR 360-3; KR 500-3AxisRange of motion, softwarelimitedSpeed withrated payload5 +/-118° 74 °/s6 +/-350° 123 °/sThe direction of motion and the arrangement of the individual axes may be notedfrom the diagram (>>> Fig. 4-1 ).Fig. 4-1: Direction of rotation of robot axesWorkingenvelopeThe diagram (>>> Fig. 4-2 ) shows the shape and size of the working envelopefor the robots:• KR 360-3• KR 360-3 F• KR 500-3• KR 500-3 FThe reference point for the working envelope is the intersection of axis 4 withaxis 5.18 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-2: Working envelope for KR 360-3, KR 500-3 (incl. F variant)The diagram (>>> Fig. 4-3 ) shows the shape and size of the working envelopefor the robot:• KR 500-3 CThe reference point for the working envelope is the intersection of axis 4 withaxis 5.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)19 / 109

KR 360-3; KR 500-3Fig. 4-3: Working envelope, KR 500-3 CThe diagram (>>> Fig. 4-4 ) shows the shape and size of the working envelopefor the robots:• KR 360 L240-3• KR 360 L240-3 F• KR 500 L340-320 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data• KR 500 L340-3 FThe reference point for the working envelope is the intersection of axis 4 withaxis 5.Fig. 4-4: Working envelope for KR 360 L240-3, KR 500 L340-3 (incl. F variant)The diagram (>>> Fig. 4-5 ) shows the shape and size of the working envelopefor the robots:• KR 360 L280-3• KR 360 L280-3 F• KR 500 L420-3Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)21 / 109

KR 360-3; KR 500-3• KR 500 L420-3 FThe reference point for the working envelope is the intersection of axis 4 withaxis 5.Fig. 4-5: Working envelope for KR 360 L280-3, KR 500 L420-3 (incl. F variant)The diagram (>>> Fig. 4-6 ) shows the shape and size of the working envelopefor the robot:• KR 500 L420-3 CThe reference point for the working envelope is the intersection of axis 4 withaxis 5.22 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-6: Working envelope for KR 500 L420-3 C4.3 PayloadsPayloadsKR 360-3The following payloads are valid for the robots:• KR 360-3Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)23 / 109

KR 360-3; KR 500-3• KR 360-3 FRobot KR 360-3Wrist IW 360-3Rated payload360 kgDistance of the load center of gravity L z300 mmDistance of the load center of gravity L xy 350 mmPermissible moment of inertia 180 kgm 2Max. total load860 kgSupplementary load, arm50 kgSupplementary load, link arm100 kgSupplementary load, rotating column400 kgThe following payloads are valid for the robots:• KR 360 L240-3• KR 360 L240-3 FRobot KR 360 L240-3Wrist IW 360-3Rated payload240 kgDistance of the load center of gravity L z300 mmDistance of the load center of gravity L xy 350 mmPermissible moment of inertia 120 kgm 2Max. total load740 kgSupplementary load, arm50 kgSupplementary load, link arm100 kgSupplementary load, rotating column400 kgThe following payloads are valid for the robots:• KR 360 L280-3• KR 360 L280-3 FRobot KR 360 L280-3Wrist IW 360-3Rated payload280 kgDistance of the load center of gravity L z300 mmDistance of the load center of gravity L xy 350 mmPermissible moment of inertia 140 kgm 2Max. total load780 kgSupplementary load, arm50 kgSupplementary load, link arm100 kgSupplementary load, rotating column400 kgPayloadsKR 500-3The following payloads are valid for the robots:• KR 500-3• KR 500-3 FRobot KR 500-3Wrist IW 500-3Rated payload500 kgDistance of the load center of gravity L z300 mm24 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataRobot KR 500-3Distance of the load center of gravity L xy 350 mmPermissible moment of inertia 250 kgm 2Max. total load1000 kgSupplementary load, arm50 kgSupplementary load, link arm100 kgSupplementary load, rotating column400 kgThe following payloads are valid for the robot:• KR 500-3 CRobotKR 500-3 CWrist IW 500-3Rated payload500 kgDistance of the load center of gravity L z300 mmDistance of the load center of gravity L xy 350 mmPermissible moment of inertia 250 kgm 2Max. total load1000 kgSupplementary load, arm50 kgSupplementary load, link arm50 kgSupplementary load, rotating column50 kgThe following payloads are valid for the robots:• KR 500 L340-3• KR 500 L340-3 FRobot KR 500 L340-3Wrist IW 500-3Rated payload340 kgDistance of the load center of gravity L z300 mmDistance of the load center of gravity L xy 350 mmPermissible moment of inertia 170 kgm 2Max. total load840 kgSupplementary load, arm50 kgSupplementary load, link arm100 kgSupplementary load, rotating column400 kgThe following payloads are valid for the robots:• KR 500 L420-3• KR 500 L420-3 FRobot KR 500 L420-3Wrist IW 500-3Rated payload420 kgDistance of the load center of gravity L z300 mmDistance of the load center of gravity L xy 350 mmPermissible moment of inertia 210 kgm 2Max. total load920 kgSupplementary load, arm50 kgIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)25 / 109

KR 360-3; KR 500-3Robot KR 500 L420-3Supplementary load, link arm100 kgSupplementary load on rotating column400 kgThe following payloads are valid for the robots:• KR 500 L420-3 CRobotKR 500 L420-3 CWrist IW 500-3Rated payload420 kgDistance of the load center of gravity L z300 mmDistance of the load center of gravity L xy 350 mmPermissible moment of inertia 210 kgm 2Max. total load920 kgSupplementary load, arm50 kgSupplementary load, link arm50 kgSupplementary load, rotating column50 kgLoad center ofgravity PFor all payloads, the load center of gravity refers to the distance from the faceof the mounting flange on axis 6. Refer to the payload diagram for the nominaldistance.Payload diagramFig. 4-7: Payload diagram for KR 360-3 (with F variant)26 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-8: Payload diagram for KR 360 L240-3 (with F variant)Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)27 / 109

KR 360-3; KR 500-3Fig. 4-9: Payload diagram for KR 360 L280-3 (with F variant)28 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-10: Payload diagram for KR 500-3 MT (with F and C variant)Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)29 / 109

KR 360-3; KR 500-3Fig. 4-11: Payload diagram for KR 500 L340-3 (with F variant)30 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-12: Payload diagram for KR 500 L420-3 (with F and C variant)This loading curve corresponds to the maximum load capacity.Both values (payload and mass moment of inertia)must be checked in all cases. Exceeding this capacity will reduce theservice life of the robot and overload the motors and the gears; in any suchcase the KUKA Roboter GmbH must be consulted beforehand.The values determined here are necessary for planning the robot application.For commissioning the robot, additional input data are required in accordancewith operating and programming instructions of the KUKA SystemSoftware.The mass inertia must be verified using KUKA.Load. It is imperative for theload data to be entered in the robot controller!Mounting flangeMounting flangeDIN/ISO 9409-1-A200Screw grade 10.9Screw sizeM12Grip length1.5 x nominal diameterDepth of engagementmin. 12 mm, max. 18 mmLocating element12 H7The mounting flange is depicted (>>> Fig. 4-13 ) with axis 6 in the zero position.The symbol X m indicates the position of the locating element (bushing) inthe zero position.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)31 / 109

KR 360-3; KR 500-3Fig. 4-13: Mounting flange1 Fitting lengthSupplementaryloadThe robot can carry supplementary loads on the arm, on the rotating columnand on the link arm. When mounting the supplementary loads, be careful toobserve the maximum permissible total load. The dimensions and positions ofthe installation options can be seen in the following diagram.Fig. 4-14: Supplementary load on arm1 Support bracket for supplementary load32 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-15: Supplementary load on rotating columnFig. 4-16: Supplementary load, link arm4.4 Foundation dataFoundation loadsThe specified forces and moments already include the payload and the inertiaforce (weight) of the robot.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)33 / 109

KR 360-3; KR 500-3Fig. 4-17: Loads acting on the mounting baseFoundationloads, KR 360-3The following foundation loads are valid for the robots:• KR 360-3 and KR 360-3 F• KR 360 L240-3 and KR 360 L240-3 F• KR 360 L280-3 and KR 360 L280-3 FType of loadF v = vertical forceF h = horizontal forceM k = tilting momentM r = torqueTotal mass for loadacting on the mounting baseForce/torque/massF vmax = 40,500 NF hmax = 23,500 NM kmax = 84,500 NmM rmax = 45,500 NmKR 360-3: 3,235 kgKR 360-3 F: 3,235 kgKR 360 L240-3: 3,151 kgKR 360 L240-3 F: 3,151 kgKR 360 L280-3: 3,185 kgKR 360 L280-3 F: 3,185 kg34 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataType of loadRobotTotal load forfoundation loadForce/torque/massKR 360-3: 2,375 kgKR 360-3 F: 2,375 kgKR 360 L240-3: 2,411 kgKR 360 L240-3 F: 2,411 kgKR 360 L280-3: 2,405 kgKR 360 L280-3 F: 2,405 kgKR 360-3: 860 kgKR 360-3 F: 860 kgKR 360 L240-3: 740 kgKR 360 L240-3 F: 740 kgKR 360 L280-3: 780 kgKR 360 L280-3 F: 780 kgFoundationloads, KR 500-3The following foundation loads are valid for the robots:• KR 500-3, KR 500-3 F and KR 500-3 C• KR 500 L340-3 and KR 500 L340-3 F• KR 500 L420-3, KR 500 L420-3 F and KR 500 L420-3 CType of loadF v = vertical forceF h = horizontal forceM k = tilting momentM r = torqueTotal mass for loadacting on the mounting baseForce/torque/massF vmax = 40,500 NF hmax = 23,500 NM kmax = 84,500 NmM rmax = 45,500 NmKR 500-3: 3,375 kgKR 500-3 F: 3,375 kgKR 500-3 C: 3,375 kgKR 500 L340-3: 3,251 kgKR 500 L340-3 F: 3,251 kgKR 500 L420-3: 3,325 kgKR 500 L420-3 F: 3,325 kgKR 500 L420-3 C: 3,325 kgIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)35 / 109

KR 360-3; KR 500-3Type of loadRobotTotal load forfoundation loadForce/torque/massKR 500-3: 2,375 kgKR 500-3 F: 2,375 kgKR 500-3 C: 2,375 kgKR 500 L340-3: 2,411 kgKR 500 L340-3 F: 2,411 kgKR 500 L420-3: 2,405 kgKR 500 L420-3 F: 2,405 kgKR 500 L420-3 C: 2,405 kgKR 500-3: 1,000 kgKR 500-3 F: 1,000 kgKR 500-3 C: 1,000 kgKR 500 L340-3: 840 kgKR 500 L340-3 F: 840 kgKR 500 L420-3: 920 kgKR 500 L420-3 F: 920 kgKR 500 L420-3 C: 920 kgThe mounting base loads specified in the table are themaximum loads that may occur. They must be referredto when dimensioning the mounting bases and must be adhered to for safetyreasons.The supplementary loads are not taken into consideration in the calculationof the foundation load. These supplementary loads must be taken into considerationfor F v .Grade of concretefor foundationsWhen producing foundations from concrete, observe the load-bearing capacityof the ground and the country-specific construction regulations. There mustbe no layers of insulation or screed between the bedplates and the concretefoundation. The quality of the concrete must meet the requirements of the followingstandard:• C20/25 according to DIN EN 206-1:2001/DIN 1045-2:20084.5 Plates and labelsPlates and labelsThe following plates and labels are attached to the robot. They must not be removedor rendered illegible. Illegible plates and labels must be replaced.36 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-18: Plates and labelsIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)37 / 109

KR 360-3; KR 500-34.6 Stopping distances and times4.6.1 General informationInformation concerning the data:• The stopping distance is the angle traveled by the robot from the momentthe stop signal is triggered until the robot comes to a complete standstill.• The stopping time is the time that elapses from the moment the stop signalis triggered until the robot comes to a complete standstill.• The data are given for the main axes A1, A2 and A3. The main axes arethe axes with the greatest deflection.• Superposed axis motions can result in longer stopping distances.• Stopping distances and stopping times in accordance with DIN EN ISO10218-1, Annex B.• Stop categories:• Stop category 0 » STOP 0• Stop category 1 » STOP 1according to IEC 60204-1• The values specified for Stop 0 are guide values determined by means oftests and simulation. They are average values which conform to the requirementsof DIN EN ISO 10218-1. The actual stopping distances andstopping times may differ due to internal and external influences on thebraking torque. It is therefore advisable to determine the exact stoppingdistances and stopping times where necessary under the real conditionsof the actual robot application.• Measuring techniqueThe stopping distances were measured using the robot-internal measuringtechnique.• The wear on the brakes varies depending on the operating mode, robotapplication and the number of STOP 0 triggered. It is therefore advisableto check the stopping distance at least once a year.4.6.2 Terms usedTermmPhiPOVExtensionKCPDescriptionMass of the rated load and the supplementary load onthe arm.Angle of rotation (°) about the corresponding axis. Thisvalue can be entered in the controller via the KCP andis displayed on the KCP.Program override (%) = velocity of the robot motion.This value can be entered in the controller via the KCPand is displayed on the KCP.Distance (l in %) (>>> Fig. 4-19 ) between axis 1 andthe intersection of axes 4 and 5. With parallelogramrobots, the distance between axis 1 and the intersectionof axis 6 and the mounting flange.The KCP teach pendant has all the operator controland display functions required for operating and programmingthe robot system.38 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-19: Extension4.6.3 Stopping distances and times, KR 360-3; KR 360-3 F4.6.3.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3The table shows the stopping distances and stopping times after a STOP 0(category 0 stop) is triggered. The values refer to the following configuration:• Extension l = 100%• Program override POV = 100%• Mass m = maximum load (rated load + supplementary load on arm)Stopping distance (°)Axis 1 57.64 1.03Axis 2 44.11 0.789Axis 3 24.57 0.379Stopping time (s)Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)39 / 109

KR 360-3; KR 500-34.6.3.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-20: Stopping distances for STOP 1, axis 140 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-21: Stopping times for STOP 1, axis 1Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)41 / 109

KR 360-3; KR 500-34.6.3.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-22: Stopping distances for STOP 1, axis 242 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-23: Stopping times for STOP 1, axis 2Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)43 / 109

KR 360-3; KR 500-34.6.3.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-24: Stopping distances for STOP 1, axis 3Fig. 4-25: Stopping times for STOP 1, axis 34.6.4 Stopping distances and times, KR 360 L240-3, KR 360 L240-3 F4.6.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3The table shows the stopping distances and stopping times after a STOP 0(category 0 stop) is triggered. The values refer to the following configuration:• Extension l = 100%• Program override POV = 100%• Mass m = maximum load (rated load + supplementary load on arm)Stopping distance (°)Axis 1 58.81 1.056Axis 2 43.91 0.799Axis 3 26.73 0.425Stopping time (s)44 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.4.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-26: Stopping distances for STOP 1, axis 1Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)45 / 109

KR 360-3; KR 500-3Fig. 4-27: Stopping times for STOP 1, axis 146 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.4.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-28: Stopping distances for STOP 1, axis 2Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)47 / 109

KR 360-3; KR 500-3Fig. 4-29: Stopping times for STOP 1, axis 248 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.4.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-30: Stopping distances for STOP 1, axis 3Fig. 4-31: Stopping times for STOP 1, axis 34.6.5 Stopping distances and times, KR 360 L280-3, KR 360 L280-3 F4.6.5.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3The table shows the stopping distances and stopping times after a STOP 0(category 0 stop) is triggered. The values refer to the following configuration:• Extension l = 100%• Program override POV = 100%• Mass m = maximum load (rated load + supplementary load on arm)Stopping distance (°)Axis 1 57.73 1.032Axis 2 43.06 0.777Axis 3 25.50 0.398Stopping time (s)Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)49 / 109

KR 360-3; KR 500-34.6.5.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-32: Stopping distances for STOP 1, axis 150 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-33: Stopping times for STOP 1, axis 1Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)51 / 109

KR 360-3; KR 500-34.6.5.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-34: Stopping distances for STOP 1, axis 252 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-35: Stopping times for STOP 1, axis 2Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)53 / 109

KR 360-3; KR 500-34.6.5.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-36: Stopping distances for STOP 1, axis 3Fig. 4-37: Stopping times for STOP 1, axis 34.6.6 Stopping distances and times, KR 500-3, KR 500-3 F, KR 500-3 C4.6.6.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3The table shows the stopping distances and stopping times after a STOP 0(category 0 stop) is triggered. The values refer to the following configuration:• Extension l = 100%• Program override POV = 100%• Mass m = maximum load (rated load + supplementary load on arm)Stopping distance (°)Axis 1 23.79 0.692Axis 2 30.94 0.666Axis 3 19.40 0.362Stopping time (s)54 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.6.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-38: Stopping distances for STOP 1, axis 1Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)55 / 109

KR 360-3; KR 500-3Fig. 4-39: Stopping times for STOP 1, axis 156 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.6.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-40: Stopping distances for STOP 1, axis 2Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)57 / 109

KR 360-3; KR 500-3Fig. 4-41: Stopping times for STOP 1, axis 258 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.6.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-42: Stopping distances for STOP 1, axis 3Fig. 4-43: Stopping times for STOP 1, axis 34.6.7 Stopping distances and times, KR 500 L340-3, KR 500 L340-3 F4.6.7.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3The table shows the stopping distances and stopping times after a STOP 0(category 0 stop) is triggered. The values refer to the following configuration:• Extension l = 100%• Program override POV = 100%• Mass m = maximum load (rated load + supplementary load on arm)Stopping distance (°)Axis 1 47.67 0.97Axis 2 36.34 0.785Axis 3 20.98 0.401Stopping time (s)Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)59 / 109

KR 360-3; KR 500-34.6.7.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-44: Stopping distances for STOP 1, axis 160 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-45: Stopping times for STOP 1, axis 1Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)61 / 109

KR 360-3; KR 500-34.6.7.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-46: Stopping distances for STOP 1, axis 262 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical dataFig. 4-47: Stopping times for STOP 1, axis 2Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)63 / 109

KR 360-3; KR 500-34.6.7.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-48: Stopping distances for STOP 1, axis 3Fig. 4-49: Stopping times for STOP 1, axis 34.6.8 Stopping distances and times, KR 500 L420-3, KR 500 L420-3 F, KR 500 L420-3 C4.6.8.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3The table shows the stopping distances and stopping times after a STOP 0(category 0 stop) is triggered. The values refer to the following configuration:• Extension l = 100%• Program override POV = 100%• Mass m = maximum load (rated load + supplementary load on arm)Stopping distance (°)Axis 1 48.17 0.982Axis 2 35.96 0.778Axis 3 20.41 0.387Stopping time (s)64 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.8.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-50: Stopping distances for STOP 1, axis 1Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)65 / 109

KR 360-3; KR 500-3Fig. 4-51: Stopping times for STOP 1, axis 166 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.8.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-52: Stopping distances for STOP 1, axis 2Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)67 / 109

KR 360-3; KR 500-3Fig. 4-53: Stopping times for STOP 1, axis 268 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

4 Technical data4.6.8.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-54: Stopping distances for STOP 1, axis 3Fig. 4-55: Stopping times for STOP 1, axis 3Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)69 / 109

KR 360-3; KR 500-370 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

5 Safety5 Safety5.1 General•This “Safety” chapter refers to a mechanical component of an industrialrobot.•If the mechanical component is used together with a KUKA robotcontroller, the “Safety” chapter of the operating instructions or assemblyinstructions of the robot controller must be used!This contains all the information provided in this “Safety” chapter. It alsocontains additional safety information relating to the robot controllerwhich must be observed.• Where this “Safety” chapter uses the term “industrial robot”, this also refersto the individual mechanical component if applicable.5.1.1 LiabilityThe device described in this document is either an industrial robot or a componentthereof.Components of the industrial robot:• Manipulator• Robot controller• Teach pendant• Connecting cables• External axes (optional)e.g. linear unit, turn-tilt table, positioner• Software• Options, accessoriesThe industrial robot is built using state-of-the-art technology and in accordancewith the recognized safety rules. Nevertheless, misuse of the industrialrobot may constitute a risk to life and limb or cause damage to the industrialrobot and to other material property.The industrial robot may only be used in perfect technical condition in accordancewith its designated use and only by safety-conscious persons who arefully aware of the risks involved in its operation. Use of the industrial robot issubject to compliance with this document and with the declaration of incorporationsupplied together with the industrial robot. Any functional disorders affectingsafety must be rectified immediately.Safety informationSafety information cannot be held against KUKA Roboter GmbH. Even if allsafety instructions are followed, this is not a guarantee that the industrial robotwill not cause personal injuries or material damage.No modifications may be carried out to the industrial robot without the authorizationof KUKA Roboter GmbH. Additional components (tools, software,etc.), not supplied by KUKA Roboter GmbH, may be integrated into the industrialrobot. The user is liable for any damage these components may cause tothe industrial robot or to other material property.In addition to the Safety chapter, this document contains further safety instructions.These must also be observed.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)71 / 109

KR 360-3; KR 500-35.1.2 Intended use of the industrial robotThe industrial robot is intended exclusively for the use designated in the “Purpose”chapter of the operating instructions or assembly instructions.Further information is contained in the “Purpose” chapter of the operatinginstructions or assembly instructions of the industrial robot.Using the industrial robot for any other or additional purpose is considered impermissiblemisuse. The manufacturer cannot be held liable for any damageresulting from such use. The risk lies entirely with the user.Operating the industrial robot and its options within the limits of its intendeduse also involves observance of the operating and assembly instructions forthe individual components, with particular reference to the maintenance specifications.MisuseAny use or application deviating from the intended use is deemed to be impermissiblemisuse. This includes e.g.:• Transportation of persons and animals• Use as a climbing aid• Operation outside the permissible operating parameters• Use in potentially explosive environments• Operation without additional safeguards• Outdoor operation• Underground operation5.1.3 EC declaration of conformity and declaration of incorporationThis industrial robot constitutes partly completed machinery as defined by theEC Machinery Directive. The industrial robot may only be put into operation ifthe following preconditions are met:• The industrial robot is integrated into a complete system.Or: The industrial robot, together with other machinery, constitutes a completesystem.Or: All safety functions and safeguards required for operation in the completemachine as defined by the EC Machinery Directive have been addedto the industrial robot.• The complete system complies with the EC Machinery Directive. This hasbeen confirmed by means of an assessment of conformity.Declaration ofconformityDeclaration ofincorporationThe system integrator must issue a declaration of conformity for the completesystem in accordance with the Machinery Directive. The declaration of conformityforms the basis for the CE mark for the system. The industrial robot mustbe operated in accordance with the applicable national laws, regulations andstandards.The robot controller is CE certified under the EMC Directive and the Low VoltageDirective.The industrial robot as partly completed machinery is supplied with a declarationof incorporation in accordance with Annex II B of the EC Machinery Directive2006/42/EC. The assembly instructions and a list of essentialrequirements complied with in accordance with Annex I are integral parts ofthis declaration of incorporation.The declaration of incorporation declares that the start-up of the partly completedmachinery remains impermissible until the partly completed machinery72 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

5 Safetyhas been incorporated into machinery, or has been assembled with other partsto form machinery, and this machinery complies with the terms of the EC MachineryDirective, and the EC declaration of conformity is present in accordancewith Annex II A.The declaration of incorporation, together with its annexes, remains with thesystem integrator as an integral part of the technical documentation of thecomplete machinery.5.1.4 Terms usedTermAxis rangeStopping distanceWorkspaceOperator(User)Danger zoneService lifeKCPKUKA smartPADManipulatorSafety zonesmartPADStop category 0Stop category 1Stop category 2System integrator(plant integrator)T1DescriptionRange 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 distanceThe stopping distance is part of the danger zone.The manipulator is allowed to move within its workspace. The workspaceis derived from the individual axis ranges.The user of the industrial robot can be the management, employer ordelegated 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 ofdelivery of the component to the customer.The service life is not affected by whether the component is used in arobot controller or elsewhere or not, as safety-relevant components arealso subject to ageing during storage.KUKA Control PanelTeach pendant for the KR C2/KR C2 edition2005The KCP has all the operator control and display functions required foroperating and programming the industrial robot.see “smartPAD”The robot arm and the associated electrical installationsThe safety zone is situated outside the danger zone.Teach pendant for the KR C4The smartPAD has all the operator control and display functionsrequired for operating and programming the industrial robot.The drives are deactivated immediately and the brakes are applied. Themanipulator and any external axes (optional) perform path-orientedbraking.Note: This stop category is called STOP 0 in this document.The manipulator and any external axes (optional) perform path-maintainingbraking. The drives are deactivated after 1 s and the brakes areapplied.Note: This stop category is called STOP 1 in this document.The drives are not deactivated and the brakes are not applied. Themanipulator and any external axes (optional) are braked with a normalbraking ramp.Note: This stop category is called STOP 2 in this document.System integrators are people who safely integrate the industrial robotinto a complete system and commission it.Test mode, Manual Reduced Velocity (

KR 360-3; KR 500-3TermT2External axisDescriptionTest mode, Manual High Velocity (> 250 mm/s permissible)Motion axis which is not part of the manipulator but which is controlledusing the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.5.2 PersonnelThe following persons or groups of persons are defined for the industrial robot:• User• PersonnelAll persons working with the industrial robot must have read and understoodthe industrial robot documentation, including the safetychapter.UserPersonnelThe 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 instructions at defined intervals.Personnel must be instructed, before any work is commenced, in the type ofwork involved and what exactly it entails as well as any hazards which may exist.Instruction must be carried out regularly. Instruction is also required afterparticular incidents or technical modifications.Personnel includes:• System integrator• Operators, subdivided into:• Start-up, maintenance and service personnel• Operating personnel• Cleaning personnelInstallation, exchange, adjustment, operation, maintenance and repairmust be performed only as specified in the operating or assemblyinstructions for the relevant component of the industrial robot and onlyby personnel specially trained for this purpose.System integratorOperatorThe industrial robot is safely integrated into a complete system by the systemintegrator.The system integrator is responsible for the following tasks:• Installing the industrial robot• Connecting the industrial robot• Performing risk assessment• Implementing the required safety functions and safeguards• Issuing the declaration of conformity• Attaching the CE mark• Creating the operating instructions for the complete systemThe operator must meet the following preconditions:• The operator must be trained for the work to be carried out.• Work on the industrial robot must only be carried out by qualified personnel.These are people who, due to their specialist training, knowledge andexperience, and their familiarization with the relevant standards, are ableto assess the work to be carried out and detect any potential hazards.74 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

5 SafetyExampleThe tasks can be distributed as shown in the following table.Tasks Operator ProgrammerSwitch robot controlleron/offSystem integratorx x xStart program x x xSelect program x x xSelect operating mode x x xCalibration(tool, base)Master the manipulator x xConfiguration x xProgramming x xStart-upMaintenanceRepairShutting downTransportationWork on the electrical and mechanical equipment of the industrial robotmay only be carried out by specially trained personnel.xxxxxxx5.3 Workspace, safety zone and danger zoneWorkspaces are to be restricted to the necessary minimum size. A workspacemust be safeguarded using appropriate safeguards.The safeguards (e.g. safety gate) must be situated inside the safety zone. Inthe case of a stop, the manipulator and external axes (optional) are brakedand come to a stop within the danger zone.The danger zone consists of the workspace and the stopping distances of themanipulator and external axes (optional). It must be safeguarded by means ofphysical safeguards to prevent danger to persons or the risk of material damage.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)75 / 109

KR 360-3; KR 500-3Fig. 5-1: Example of axis range A11 Workspace 3 Stopping distance2 Manipulator 4 Safety zone5.4 Overview of protective equipmentThe protective equipment of the mechanical component may include:• Mechanical end stops• Mechanical axis range limitation (optional)• Axis range monitoring (optional)• Release device (optional)• Labeling of danger areasNot all equipment is relevant for every mechanical component.5.4.1 Mechanical end stopsDepending on the robot variant, the axis ranges of the main and wrist axes ofthe manipulator are partially limited by mechanical end stops.Additional mechanical end stops can be installed on the external axes.If the manipulator or an external axis hits an obstructionor a mechanical end stop or axis range limitation, thiscan result in material damage to the industrial robot. The manipulator mustbe taken out of operation and KUKA Roboter GmbH must be consulted beforeit is put back into operation (>>> 8 "KUKA Service" Page 97).5.4.2 Mechanical axis range limitation (optional)Some manipulators can be fitted with mechanical axis range limitation in axesA1 to A3. The adjustable axis range limitation systems restrict the workingrange to the required minimum. This increases personal safety and protectionof the system.76 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

5 SafetyIn the case of manipulators that are not designed to be fitted with mechanicalaxis range limitation, the workspace must be laid out in such a way that thereis no danger to persons or material property, even in the absence of mechanicalaxis range limitation.If this is not possible, the workspace must be limited by means of photoelectricbarriers, photoelectric curtains or obstacles on the system side. There must beno shearing or crushing hazards at the loading and transfer areas.This option is not available for all robot models. Information on specificrobot models can be obtained from KUKA Roboter GmbH.5.4.3 Axis range monitoring (optional)Einige Manipulatoren können in den Grundachsen A1 bis A3 mit 2-kanaligenAchsbereichsüberwachungen ausgerüstet werden. Die Positioniererachsenkönnen mit weiteren Achsbereichsüberwachungen ausgerüstet sein. Mit einerAchsbereichsüberwachung kann für eine Achse der Schutzbereich eingestelltund überwacht werden. Damit wird der Personen- und Anlagenschutz erhöht.This option is not available for the KR C4. This option is not availablefor all robot models. Information on specific robot models can be obtainedfrom KUKA Roboter GmbH.5.4.4 Options for moving the manipulator without drive energyThe system user is responsible for ensuring that the training of personnelwith regard to the response to emergencies or exceptional situationsalso includes how the manipulator can be moved withoutdrive energy.DescriptionThe following options are available for moving the manipulator without driveenergy after an accident or malfunction:• Release device (optional)The release device can be used for the main axis drive motors and, dependingon the robot variant, also for the wrist axis drive motors.• Brake release device (option)The brake release device is designed for robot variants whose motors arenot freely accessible.• Moving the wrist axes directly by handThere is no release device available for the wrist axes of variants in the lowpayload category. This is not necessary because the wrist axes can bemoved directly by hand.Information about the options available for the various robot modelsand about how to use them can be found in the assembly and operatinginstructions for the robot or requested from KUKA RoboterGmbH.Moving the manipulator without drive energy can damagethe motor brakes of the axes concerned. The motormust be replaced if the brake has been damaged. The manipulator maytherefore be moved without drive energy only in emergencies or exceptionalsituations, e.g. for rescuing persons.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)77 / 109

KR 360-3; KR 500-35.4.5 Labeling on the industrial robotAll plates, labels, symbols and marks constitute safety-relevant parts of the industrialrobot. They must not be modified or removed.Labeling on the industrial robot consists of:• Identification plates• Warning labels• Safety symbols• Designation labels• Cable markings• Rating platesFurther information is contained in the technical data of the operatinginstructions or assembly instructions of the components of the industrialrobot.5.5 Safety measures5.5.1 General safety measuresThe industrial robot may only be used in perfect technical condition in accordancewith its intended use and only by safety-conscious persons. Operatorerrors can result in personal injury and damage to property.It is important to be prepared for possible movements of the industrial roboteven after the robot controller has been switched off and locked out. Incorrectinstallation (e.g. overload) or mechanical defects (e.g. brake defect) can causethe manipulator or external axes to sag. If work is to be carried out on aswitched-off industrial robot, the manipulator and external axes must first bemoved into a position in which they are unable to move on their own, whetherthe payload is mounted or not. If this is not possible, the manipulator and externalaxes must be secured by appropriate means.In the absence of operational safety functions and safeguards,the industrial robot can cause personal injury ormaterial damage. If safety functions or safeguards are dismantled or deactivated,the industrial robot may not be operated.Standing underneath the robot arm can cause death orserious injuries. For this reason, standing underneath therobot arm is prohibited!The motors reach temperatures during operation whichcan cause burns to the skin. Contact must be avoided.Appropriate safety precautions must be taken, e.g. protective gloves must beworn.KCP/smartPADThe user must ensure that the industrial robot is only operated with the KCP/smartPAD by authorized persons.If more than one KCP/smartPAD is used in the overall system, it must be ensuredthat each device is unambiguously assigned to the corresponding industrialrobot. They must not be interchanged.78 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

5 SafetyThe operator must ensure that decoupled KCPs/smart-PADs are immediately removed from the system andstored out of sight and reach of personnel working on the industrial robot.This serves to prevent operational and non-operational EMERGENCY STOPdevices from becoming interchanged.Failure to observe this precaution may result in death, severe injuries or considerabledamage to property.Externalkeyboard,external mouseAn external keyboard and/or external mouse may only be used if the followingconditions are met:• Start-up or maintenance work is being carried out.• The drives are switched off.• There are no persons in the danger zone.The KCP/smartPAD must not be used as long as an external keyboard and/orexternal mouse are connected.The external keyboard and/or external mouse must be removed as soon asthe start-up or maintenance work is completed or the KCP/smartPAD is connected.ModificationsFaultsAfter modifications to the industrial robot, checks must be carried out to ensurethe required safety level. The valid national or regional work safety regulationsmust be observed for this check. The correct functioning of all safety circuitsmust also be tested.New or modified programs must always be tested first in Manual Reduced Velocitymode (T1).After modifications to the industrial robot, existing programs must always betested first in Manual Reduced Velocity mode (T1). This applies to all componentsof the industrial robot and includes modifications to the software andconfiguration settings.The following tasks must be carried out in the case of faults in the industrialrobot:• Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized 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.5.5.2 TransportationManipulatorRobot controllerExternal axis(optional)The prescribed transport position of the manipulator must be observed. Transportationmust be carried out in accordance with the operating instructions orassembly instructions of the robot.The prescribed transport position of the robot controller must be observed.Transportation must be carried out in accordance with the operating instructionsor assembly instructions of the robot controller.Avoid vibrations and impacts during transportation in order to prevent damageto the robot controller.The prescribed transport position of the external axis (e.g. KUKA linear unit,turn-tilt table, positioner) must be observed. Transportation must be carriedout in accordance with the operating instructions or assembly instructions ofthe external axis.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)79 / 109

KR 360-3; KR 500-35.5.3 Start-up and recommissioningBefore starting up systems and devices for the first time, a check must be carriedout 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 thischeck. The correct functioning of all safety circuits must also be tested.The passwords for logging onto the KUKA System Software as “Expert”and “Administrator” must be changed before start-up and mustonly be communicated to authorized personnel.The robot controller is preconfigured for the specific industrial robot.If cables are interchanged, the manipulator and the external axes (optional)may receive incorrect data and can thus cause personal injuryor material damage. If a system consists of more than one manipulator, alwaysconnect the connecting cables to the manipulators and their correspondingrobot controllers.If additional components (e.g. cables), which are not part of the scopeof supply of KUKA Roboter GmbH, are integrated into the industrialrobot, the user is responsible for ensuring that these components donot adversely affect or disable safety functions.If the internal cabinet temperature of the robot controllerdiffers greatly from the ambient temperature, condensationcan form, which may cause damage to the electrical components. Do notput the robot controller into operation until the internal temperature of thecabinet has adjusted to the ambient temperature.Function testMachine dataThe following tests must be carried out before start-up and recommissioning:It must be ensured that:• The industrial robot is correctly installed and fastened in accordance withthe specifications in the documentation.• There are no foreign bodies or loose parts on the industrial robot.• All required safety equipment is correctly installed and operational.• The power supply ratings of the industrial robot correspond to the localsupply voltage and mains type.• The ground conductor and the equipotential bonding cable are sufficientlyrated and correctly connected.• The connecting cables are correctly connected and the connectors arelocked.It must be ensured that the rating plate on the robot controller has the samemachine data as those entered in the declaration of incorporation. The machinedata on the rating plate of the manipulator and the external axes (optional)must be entered during start-up.The industrial robot must not be moved if incorrect machinedata are loaded. Death, severe injuries or considerabledamage to property may otherwise result. The correct machine datamust be loaded.80 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

5 Safety5.5.4 Manual modeManual mode is the mode for setup work. Setup work is all the tasks that haveto be carried out on the industrial robot to enable automatic operation. Setupwork includes:• Jog mode• Teach• Programming• Program verificationThe following must be taken into consideration in manual mode:• If the drives are not required, they must be switched off to prevent the manipulatoror the external axes (optional) from being moved unintentionally.New or modified programs must always be tested first in Manual ReducedVelocity mode (T1).• The manipulator, tooling or external axes (optional) must never touch orproject beyond the safety fence.• Workpieces, tooling and other objects must not become jammed as a resultof the industrial robot motion, nor must they lead to short-circuits or beliable to fall off.• All setup work must be carried out, where possible, from outside the safeguardedarea.If the setup work has to be carried out inside the safeguarded area, the followingmust be taken into consideration:In Manual Reduced Velocity mode (T1):• If it can be avoided, there must be no other persons inside the safeguardedarea.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 areaand 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 velocityhigher than Manual Reduced Velocity.• Teaching and programming are not permissible in this operating mode.• Before commencing the test, the operator must ensure that the enablingdevices are operational.• The operator must be positioned outside the danger zone.• There must be no other persons inside the safeguarded area. It is the responsibilityof the operator to ensure this.5.5.5 Automatic modeAutomatic mode is only permissible in compliance with the following safetymeasures:• All safety equipment and safeguards are present and operational.• There are no persons in the system.• The defined working procedures are adhered to.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)81 / 109

KR 360-3; KR 500-3If the manipulator or an external axis (optional) comes to a standstill for no apparentreason, the danger zone must not be entered until an EMERGENCYSTOP has been triggered.5.5.6 Maintenance and repairAfter maintenance and repair work, checks must be carried out to ensure therequired safety level. The valid national or regional work safety regulationsmust be observed for this check. The correct functioning of all safety functionsmust also be tested.The purpose of maintenance and repair work is to ensure that the system iskept operational or, in the event of a fault, to return the system to an operationalstate. Repair work includes troubleshooting in addition to the actual repairitself.The following safety measures must be carried out when working on the industrialrobot:• Carry out work outside the danger zone. If work inside the danger zone isnecessary, the user must define additional safety measures to ensure thesafe protection of personnel.• Switch off the industrial robot and secure it (e.g. with a padlock) to preventit from being switched on again. If it is necessary to carry out work with therobot controller switched on, the user must define additional safety measuresto ensure the safe protection of personnel.• If it is necessary to carry out work with the robot controller switched on, thismay only be done in operating mode T1.• Label the system with a sign indicating that work is in progress. This signmust remain in place, even during temporary interruptions to the work.• The EMERGENCY STOP systems must remain active. If safety functionsor safeguards are deactivated during maintenance or repair work, theymust be reactivated immediately after the work is completed.Before work is commenced on live parts of the robot system,the main switch must be turned off and securedagainst being switched on again by unauthorized personnel. The incomingpower cable must be deenergized. The robot controller and mains supplylead must then be checked to ensure that it is deenergized.If the KR C4 or VKR C4 robot controller is used:It is not sufficient, before commencing work on live parts, to execute anEMERGENCY STOP or a safety stop, or to switch off the drives, as this doesnot disconnect the robot system from the mains power supply in the case ofthe drives of the new generation. Parts remain energized. Death or severeinjuries may result.Faulty components must be replaced using new components with the samearticle numbers or equivalent components approved by KUKA Roboter GmbHfor this purpose.Cleaning and preventive maintenance work is to be carried out in accordancewith the operating instructions.Robot controllerEven when the robot controller is switched off, parts connected to peripheraldevices may still carry voltage. The external power sources must therefore beswitched off if work is to be carried out on the robot controller.The ESD regulations must be adhered to when working on components in therobot controller.Voltages in excess of 50 V (up to 600 V) can be present in various componentsfor several minutes after the robot controller has been switched off! To prevent82 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

5 Safetylife-threatening injuries, no work may be carried out on the industrial robot inthis time.Water and dust must be prevented from entering the robot controller.CounterbalancingsystemHazardoussubstancesSome robot variants are equipped with a hydropneumatic, spring or gas cylindercounterbalancing system.The hydropneumatic and gas cylinder counterbalancing systems are pressureequipment and, as such, are subject to obligatory equipment monitoring. Dependingon the robot variant, the counterbalancing systems correspond to category0, II or III, fluid group 2, of the Pressure Equipment Directive.The user must comply with the applicable national laws, regulations and standardspertaining to pressure equipment.Inspection intervals in Germany in accordance with Industrial Safety Order,Sections 14 and 15. Inspection by the user before commissioning at the installationsite.The following safety measures must be carried out when working on the counterbalancingsystem:• The manipulator assemblies supported by the counterbalancing systemsmust be secured.• Work on the counterbalancing systems must only be carried out by qualifiedpersonnel.The following safety measures must be carried out when handling hazardoussubstances:• 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 that our customersregularly request up-to-date safety data sheets from the manufacturersof hazardous substances.5.5.7 Decommissioning, storage and disposalThe industrial robot must be decommissioned, stored and disposed of in accordancewith the applicable national laws, regulations and standards.5.6 Applied norms and regulationsName Definition Edition2006/42/EC Machinery Directive:Directive 2006/42/EC of the European Parliament and ofthe Council of 17 May 2006 on machinery, and amendingDirective 95/16/EC (recast)20062004/108/ECEMC Directive:Directive 2004/108/EC of the European Parliament and ofthe Council of 15 December 2004 on the approximation ofthe laws of the Member States relating to electromagneticcompatibility and repealing Directive 89/336/EEC2004Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)83 / 109

KR 360-3; KR 500-3Name Definition Edition97/23/ECEN ISO 13850EN ISO 13849-1EN ISO 13849-2EN ISO 12100EN ISO 10218-1EN 614-1EN 61000-6-2EN 61000-6-4EN 60204-1Pressure Equipment Directive:Directive 97/23/EC of the European Parliament and of theCouncil of 29 May 1997 on the approximation of the lawsof the Member States concerning pressure equipment(Only applicable for robots with hydropneumatic counterbalancingsystem.)Safety of machinery:Emergency stop - Principles for designSafety of machinery:Safety-related parts of control systems - Part 1: Generalprinciples of designSafety of machinery:Safety-related parts of control systems - Part 2: ValidationSafety of machinery:General principles of design, risk assessment and riskreductionIndustrial robots:SafetySafety of machinery:Ergonomic design principles - Part 1: Terms and generalprinciplesElectromagnetic compatibility (EMC):Part 6-2: Generic standards; Immunity for industrial environmentsElectromagnetic compatibility (EMC):Part 6-4: Generic standards; Emission standard for industrialenvironmentsSafety of machinery:Electrical equipment of machines - Part 1: Generalrequirements199720082008200820102011200620052007200684 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

6 Planning6 Planning6.1 Mounting base 175 mmDescriptionThe mounting base with centering (>>> Fig. 6-1 ) is used when the robot isfastened to the floor, i.e. directly on a concrete foundation with a thickness ofat least 175 mm.The mounting base consists of:• Bedplate• Chemical anchors (resin-bonded anchors) with Dynamic Set• FastenersThis mounting variant requires a level and smooth surface on a concrete foundationwith adequate load bearing capacity. The concrete foundation must beable to accommodate the forces occurring during operation. The minimum dimensionsmust be observed.Fig. 6-1: Mounting base 175 mm1 Concrete foundation 4 Hexagon bolt2 Chemical anchor (resin-bonded5 Bedplateanchor)3 PinGrade of concretefor foundationsDimensioneddrawingWhen producing foundations from concrete, observe the load-bearing capacityof the ground and the country-specific construction regulations. There mustbe no layers of insulation or screed between the bedplates and the concretefoundation. The quality of the concrete must meet the requirements of the followingstandard:• C20/25 according to DIN EN 206-1:2001/DIN 1045-2:2008The following illustration provides all the necessary information on the mountingbase, together with the required foundation data.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)85 / 109

KR 360-3; KR 500-3Fig. 6-2: Mounting base 175 mm, dimensioned drawing1 Robot 2 BedplateTo ensure that the anchor forces are safely transmitted to the foundation, observethe dimensions for concrete foundations specified in the following illustration(>>> Fig. 6-3 ).Fig. 6-3: Cross-section of foundation 175 mm1 Bedplate2 Chemical anchors (resin-bonded anchors) with Dynamic Set3 Concrete foundation86 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

6 Planning6.2 Mounting base 200 mmDescriptionThe mounting base with centering (>>> Fig. 6-4 ) is used when the robot isfastened to the floor, i.e. directly on a concrete foundation with a thickness ofat least 200 mm.The mounting base with centering consists of:• Bedplates• Chemical anchors• Fastening elementsThis mounting variant requires a level and smooth surface on a concrete foundationwith adequate load bearing capacity. The concrete foundation must beable to accommodate the forces occurring during operation. There must be nolayers of insulation or screed between the bedplates and the concrete foundation.The minimum dimensions must be observed.Fig. 6-4: Mounting base 200 mm1 Bedplate 3 Pin with Allen screw2 Hexagon bolt 4 Resin-bonded anchors withDynamic SetGrade of concretefor foundationsDimensioneddrawingWhen producing foundations from concrete, observe the load-bearing capacityof the ground and the country-specific construction regulations. There mustbe no layers of insulation or screed between the bedplates and the concretefoundation. The quality of the concrete must meet the requirements of the followingstandard:• C20/25 according to DIN EN 206-1:2001/DIN 1045-2:2008The following illustrations provide all the necessary information on the mountingbase, together with the required foundation data.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)87 / 109

KR 360-3; KR 500-3Fig. 6-5: Mounting base 200 mm, dimensioned drawing1 Bedplates 2 RobotTo ensure that the anchor forces are safely transmitted to the foundation, observethe dimensions for concrete foundations specified in the following illustration.Fig. 6-6: Cross-section of foundation 200 mm1 Hexagon bolt 4 Concrete foundation2 Pin 5 Resin-bonded anchor3 Bedplate88 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

6 Planning6.3 Machine frame mountingDescriptionThe machine frame mounting assembly is used when the robot is fastened ona steel structure, a booster frame (pedestal) or a KUKA linear unit. This assemblyis also used if the manipulator is installed in an inverted position, i.e.on the ceiling. It must be ensured that the substructure is able to withstandsafely the forces occurring during operation (foundation loads). The followingdiagram contains all the necessary information that must be observed whenpreparing the mounting surface (>>> Fig. 6-7 ).The machine frame mounting assembly consists of:• Pin with fasteners• Hexagon bolts with conical spring washersFig. 6-7: Machine frame mounting1 Pin2 Hexagon boltDimensioneddrawingThe following illustrations provide all the necessary information on machineframe mounting, together with the required foundation data.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)89 / 109

KR 360-3; KR 500-3Fig. 6-8: Machine frame mounting, dimensioned drawing1 Steel structure 3 Hexagon bolt (8x)2 Pins (2x) 4 Mounting surface6.4 Connecting cables and interfacesConnectingcablesThe connecting cables comprise all the cables for transferring energy and signalsbetween the robot and the robot controller. They are connected to the robotjunction boxes with connectors. The set of connecting cables comprises:• Motor cable X20.1 - X30.1• Motor cable X20.4 - X30.4• Control cable X21 - X31• Ground conductor (optional)Depending on the specification of the robot, various connecting cables areused. Cable lengths of 7 m, 15 m, 25 m, 35 m and 50 m are available. Themaximum length of the connecting cables must not exceed 50 m. Thus if therobot is operated on a linear unit which has its own energy supply chain thesecables must also be taken into account.90 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

6 PlanningFor the connecting cables, a ground conductor is always required toprovide a low-resistance connection between the robot and the controlcabinet in accordance with DIN EN 60204. The ground conductoris not part of the scope of supply and can be ordered as an option. The connectionmust be made by the customer. The tapped holes for connecting theground conductor are located on the base frame of the robot.The following points must be observed when planning and routing the connectingcables:• The bending radius for fixed routing must not be less than 150 mm for motorcables and 60 mm for control cables.• 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 permissible temperature range (fixed installation) of 263 K (-10 °C) to 343 K (+70 °C).• Route the motor cables and the data cables separately in metal ducts; ifnecessary, additional measures must be taken to ensure electromagneticcompatibility (EMC).Interface forenergy supplysystemsThe robot can be equipped with an energy supply system between axis 1 andaxis 3 and a second energy supply system between axis 3 and axis 6. The A1interface required for this is located on the rear of the base frame, the A3 interfaceis located on the side of the arm and the interface for axis 6 is locatedon the robot tool. Depending on the application, the interfaces differ in designand scope. They can be equipped e.g. with connections for cables and hoses.Detailed information on the connector pin allocation, threaded unions, etc. isgiven in separate documentation.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)91 / 109

KR 360-3; KR 500-3Fig. 6-9: Connecting cables and interfaces1 Interface A6, tool2 Interface A3, arm3 Connection, motor cable X30.44 Connection, motor cable X30.15 Connection, control cable X316 Interface A1, base frame92 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

7 Transportation7 Transportation7.1 Transporting the robotDescriptionTransportpositionMove the robot into its transport position each time it is transported. It must beensured that the robot is stable while it is being transported. The robot mustremain in its transport position until it has been fastened in position. Before therobot is lifted, it must be ensured that it is free from obstructions. Remove alltransport safeguards, such as nails and screws, in advance. First remove anyrust or glue on contact surfaces. Remove any disruptive add-on parts (e.g. energysupply system) before transportation.The robot must be in the transport position (>>> Fig. 7-1 ) before it can betransported. The robot is in the transport position when the axes are in the followingpositions:Axis A1 A2 A3 A4 A5 A6Angle 0° -130° +130° 0º +90º 0ºFig. 7-1: Transport positionTransport dimensionsThe transport dimensions for the robot can be noted from the following figures.The position of the center of gravity and the weight vary according to the specificconfiguration. The specified dimensions refer to the robot without equipment.Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)93 / 109

KR 360-3; KR 500-3Fig. 7-2: Transport dimensions1 Robot 3 Fork slots2 Center of gravityRobot A B C DKR 360-31,803 mm 1,053 mm 78 mm 77 mmKR 360-3 FKR 360 L240-3 2,290 mm 1,069 mm 122 mm 77 mmKR 360 L240-3 FKR 360 L280-3 2,040 mm 1,059 mm 100 mm 77 mmKR 360 L280-3 FKR 500-31,803 mm 1,053 mm 78 mm 77 mmKR 500-3 FKR 500-3 CKR 500 L340-3 2,290 mm 1,069 mm 122 mm 77 mmKR 500 L340-3 FKR 500 L420-3KR 500 L420-3 FKR 500 L420-3 C2,040 mm 1,059 mm 100 mm 77 mmTransportationThe robot can be transported by fork lift truck or using lifting tackle.Use of unsuitable handling equipment may result in damageto the robot or injury to persons. Only use authorizedhandling equipment with a sufficient load-bearing capacity. Only transportthe robot in the manner specified here.94 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

7 TransportationTransportation byfork lift truckFor transport by fork lift truck (>>> Fig. 7-3 ), two fork slots are provided in thebase frame. The robot can be picked up by the fork lift truck from the front andrear. The base frame must not be damaged when inserting the forks into thefork slots. The fork lift truck must have a minimum payload capacity of3,500 kg and an adequate fork length.Ceiling-mounted robots can only be transported by fork lift truck.Avoid excessive loading of the fork slots through undueinward or outward movement of hydraulically adjustableforks of the fork lift truck. Failure to do so may result in material damage.Fig. 7-3: Transportation by fork lift truckTransportationwith lifting tackleThe robot can also be transported using lifting tackle. The robot must be in thetransport position.The lifting tackle must be attached using 3 M20 DIN 580 eyebolts and positionedalong the robot as illustrated (>>> Fig. 7-4 ). The lifting tackle mustconsist of 3 legs of the following length:• Length of leg G1: 2020 mm• Length of leg G2: 2140 mm• Length of leg G3: 1480 mmAll the legs must be long enough and must be routed in such a way that therobot is not damaged. Installed tools and items of equipment that could bedamaged during transportation must be removed.Installed tools and items of equipment can cause undesirable shifts in the centerof gravity, which are liable to cause a collision during transportation. Theuser shall be liable for any damage to the robot or to other material propertyresulting from this.Tools and items of equipment must be removed from a robot before it is exchanged.The robot may tip during transportation. Risk of personalinjury and damage to property.If the robot is being transported using lifting tackle, special care must be exercisedto prevent it from tipping. Additional safeguarding measures must betaken. It is forbidden to pick up the robot in any other way using a crane!Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)95 / 109

KR 360-3; KR 500-3Fig. 7-4: Transportation using lifting tackle1 Lifting tackle assembly2 Leg G1 (length: 2020 mm)3 M20 DIN 580 eyebolt4 Leg G2 (length: 2140 mm)5 Leg G3 (length: 1480 mm)96 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

8 KUKA Service8 KUKA Service8.1 Requesting supportIntroductionInformationThe KUKA Roboter GmbH documentation offers information on operation andprovides assistance with troubleshooting. For further assistance, please contactyour local KUKA subsidiary.The following information is required for processing a support request:• Model and serial number of the manipulator• Model and serial number of the controller• Model and serial number of the linear unit (if applicable)• Model and serial number of the energy supply system (if applicable)• Version of the KUKA System Software• Optional software or modifications• Archive of the software• Application used• Any external axes used (if applicable)• Description of the problem, duration and frequency of the fault8.2 KUKA Customer SupportAvailabilityKUKA Customer Support is available in many countries. Please do not hesitateto contact us if you have any questions.ArgentinaRuben Costantini S.A. (Agency)Luis Angel Huergo 13 20Parque Industrial2400 San Francisco (CBA)ArgentinaTel. +54 3564 421033Fax +54 3564 428877ventas@costantini-sa.comAustraliaHeadland Machinery Pty. Ltd.Victoria (Head Office & Showroom)95 Highbury RoadBurwoodVictoria 31 25AustraliaTel. +61 3 9244-3500Fax +61 3 9244-3501vic@headland.com.auwww.headland.com.auIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)97 / 109

KR 360-3; KR 500-3BelgiumKUKA Automatisering + Robots N.V.Centrum Zuid 10313530 HouthalenBelgiumTel. +32 11 516160Fax +32 11 526794info@kuka.bewww.kuka.beBrazilKUKA Roboter do Brasil Ltda.Travessa Claudio Armando, nº 171Bloco 5 - Galpões 51/52Bairro AssunçãoCEP 09861-7630 São Bernardo do Campo - SPBrazilTel. +55 11 4942-8299Fax +55 11 2201-7883info@kuka-roboter.com.brwww.kuka-roboter.com.brChileRobotec S.A. (Agency)Santiago de ChileChileTel. +56 2 331-5951Fax +56 2 331-5952robotec@robotec.clwww.robotec.clChinaKUKA Robotics China Co.,Ltd.Songjiang Industrial ZoneNo. 388 Minshen Road201612 ShanghaiChinaTel. +86 21 6787-1888Fax +86 21 6787-1803www.kuka-robotics.cnGermanyKUKA Roboter GmbHZugspitzstr. 14086165 AugsburgGermanyTel. +49 821 797-4000Fax +49 821 797-1616info@kuka-roboter.dewww.kuka-roboter.de98 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

8 KUKA ServiceFranceKUKA Automatisme + Robotique SASTechvallée6, Avenue du Parc91140 Villebon S/YvetteFranceTel. +33 1 6931660-0Fax +33 1 6931660-1commercial@kuka.frwww.kuka.frIndiaKUKA Robotics India Pvt. Ltd.Office Number-7, German Centre,Level 12, Building No. - 9BDLF Cyber City Phase III122 002 GurgaonHaryanaIndiaTel. +91 124 4635774Fax +91 124 4635773info@kuka.inwww.kuka.inItalyKUKA Roboter Italia S.p.A.Via Pavia 9/a - int.610098 Rivoli (TO)ItalyTel. +39 011 959-5013Fax +39 011 959-5141kuka@kuka.itwww.kuka.itJapanKUKA Robotics Japan K.K.YBP Technical Center134 Godo-cho, Hodogaya-kuYokohama, Kanagawa240 0005JapanTel. +81 45 744 7691Fax +81 45 744 7696info@kuka.co.jpCanadaKUKA Robotics Canada Ltd.6710 Maritz Drive - Unit 4MississaugaL5W 0A1OntarioCanadaTel. +1 905 670-8600Fax +1 905 670-8604info@kukarobotics.comwww.kuka-robotics.com/canadaIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)99 / 109

KR 360-3; KR 500-3KoreaKUKA Robotics Korea Co. Ltd.RIT Center 306, Gyeonggi Technopark1271-11 Sa 3-dong, Sangnok-guAnsan City, Gyeonggi Do426-901KoreaTel. +82 31 501-1451Fax +82 31 501-1461info@kukakorea.comMalaysiaKUKA Robot Automation Sdn BhdSouth East Asia Regional OfficeNo. 24, Jalan TPP 1/10Taman Industri Puchong47100 PuchongSelangorMalaysiaTel. +60 3 8061-0613 or -0614Fax +60 3 8061-7386info@kuka.com.myMexicoKUKA de México S. de R.L. de C.V.Progreso #8Col. Centro Industrial Puente de VigasTlalnepantla de Baz54020 Estado de MéxicoMexicoTel. +52 55 5203-8407Fax +52 55 5203-8148info@kuka.com.mxwww.kuka-robotics.com/mexicoNorwayKUKA Sveiseanlegg + RoboterSentrumsvegen 52867 HovNorwayTel. +47 61 18 91 30Fax +47 61 18 62 00info@kuka.noAustriaKUKA Roboter Austria GmbHVertriebsbüro ÖsterreichRegensburger Strasse 9/14020 LinzAustriaTel. +43 732 784752Fax +43 732 793880office@kuka-roboter.atwww.kuka-roboter.at100 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

8 KUKA ServicePolandKUKA Roboter Austria GmbHSpółka z ograniczoną odpowiedzialnościąOddział w PolsceUl. Porcelanowa 1040-246 KatowicePolandTel. +48 327 30 32 13 or -14Fax +48 327 30 32 26ServicePL@kuka-roboter.dePortugalKUKA Sistemas de Automatización S.A.Rua do Alto da Guerra n° 50Armazém 042910 011 SetúbalPortugalTel. +351 265 729780Fax +351 265 729782kuka@mail.telepac.ptRussiaOOO KUKA Robotics RusWebnaja ul. 8A107143 MoskauRussiaTel. +7 495 781-31-20Fax +7 495 781-31-19kuka-robotics.ruSwedenKUKA Svetsanläggningar + Robotar ABA. Odhners gata 15421 30 Västra FrölundaSwedenTel. +46 31 7266-200Fax +46 31 7266-201info@kuka.seSwitzerlandKUKA Roboter Schweiz AGIndustriestr. 95432 NeuenhofSwitzerlandTel. +41 44 74490-90Fax +41 44 74490-91info@kuka-roboter.chwww.kuka-roboter.chIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)101 / 109

KR 360-3; KR 500-3SpainKUKA Robots IBÉRICA, S.A.Pol. IndustrialTorrent de la PasteraCarrer del Bages s/n08800 Vilanova i la Geltrú (Barcelona)SpainTel. +34 93 8142-353Fax +34 93 8142-950Comercial@kuka-e.comwww.kuka-e.comSouth AfricaJendamark Automation LTD (Agency)76a York RoadNorth End6000 Port ElizabethSouth AfricaTel. +27 41 391 4700Fax +27 41 373 3869www.jendamark.co.zaTaiwanKUKA Robot Automation Taiwan Co., Ltd.No. 249 Pujong RoadJungli City, Taoyuan County 320Taiwan, R. O. C.Tel. +886 3 4331988Fax +886 3 4331948info@kuka.com.twwww.kuka.com.twThailandKUKA Robot Automation (M)SdnBhdThailand Officec/o Maccall System Co. Ltd.49/9-10 Soi Kingkaew 30 Kingkaew RoadTt. Rachatheva, A. BangpliSamutprakarn10540 ThailandTel. +66 2 7502737Fax +66 2 6612355atika@ji-net.comwww.kuka-roboter.deCzech RepublicKUKA Roboter Austria GmbHOrganisation Tschechien und SlowakeiSezemická 2757/2193 00 PrahaHorní PočerniceCzech RepublicTel. +420 22 62 12 27 2Fax +420 22 62 12 27 0support@kuka.cz102 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

8 KUKA ServiceHungaryKUKA Robotics Hungaria Kft.Fö út 1402335 TaksonyHungaryTel. +36 24 501609Fax +36 24 477031info@kuka-robotics.huUSAKUKA Robotics Corporation51870 Shelby ParkwayShelby Township48315-1787MichiganUSATel. +1 866 873-5852Fax +1 866 329-5852info@kukarobotics.comwww.kukarobotics.comUKKUKA Automation + RoboticsHereward RiseHalesowenB62 8ANUKTel. +44 121 585-0800Fax +44 121 585-0900sales@kuka.co.ukIssued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)103 / 109

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IndexIndexNumbers2004/108/EC 832006/42/EC 8389/336/EEC 8395/16/EC 8397/23/EC 84AAccessories 9, 71Ambient temperature, operation 15Ambient temperature, start-up 15Ambient temperature, storage 15Ambient temperature, transportation 15Angle of rotation 38Applied norms and regulations 83Arm 9, 10Automatic mode 81Axes, number 13Axis data 16Axis range 73Axis range limitation 76Axis range monitoring 77BBase frame 9, 11Basic data 13Brake defect 78Brake release device 77Braking distance 6, 73CCE mark 72Center of gravity 93Cleaning work 82Connecting cables 9, 15, 71, 90Counterbalancing system 9, 11, 83Counterbalancing system, hydropneumatic 11DDanger zone 73Declaration of conformity 72Declaration of incorporation 71, 72Decommissioning 83Dimensions, transport 93DIN EN 60204-20.2 15Disposal 83Documentation, industrial robot 5Dynamic principal loads 13Dynamic Set 85EEC declaration of conformity 72Electrical installations 9EMC Directive 72, 83EN 60204-1 84EN 61000-6-2 84EN 61000-6-4 84EN 614-1 84EN ISO 10218-1 84EN ISO 12100 84EN ISO 13849-1 84EN ISO 13849-2 84EN ISO 13850 84Extension 38External axes 71, 74FFaults 79Fork lift truck 94Foundation loads 33Foundry robots 15Foundry, equipment 15Function test 80GGeneral information 38General safety measures 78Ground conductor 15HHandling equipment 94Hazardous substances 83Humidity rating 15IIn-line wrist 9, 10Industrial robot 71Intended use 72Interface, energy supply systems 91Interfaces 90Introduction 5ISO 9283, repeatability 13KKCP 6, 73, 78KCP, KUKA Control Panel 38Keyboard, external 79KUKA Customer Support 97KUKA smartPAD 6, 73LLabeling 78Liability 71Lifting tackle 94, 95Linear unit 71Link arm 9, 11Low Voltage Directive 72MMachine data 80Machine frame mounting 89Machinery Directive 72, 83main axes 38Maintenance 82Manipulator 6, 71, 73, 76Manual mode 81Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)105 / 109

KR 360-3; KR 500-3Mechanical axis range limitation 76Mechanical end stops 76Mounting base 175 mm 85Mounting base 200 mm 87Mounting flange 10, 31Mounting position 13Mouse, external 79OOperator 73, 74Options 9, 11, 71Overload 78Overview of the robot system 9PPayload diagram 26Payloads 23Personnel 74Plant integrator 73Plates and labels 36Positioner 71Pressure Equipment Directive 11, 83, 84Pressure regulator 15Preventive maintenance work 82Principal components 9Product description 9Program override, motion velocity 38Protection classification, “F” in-line wrist 13Protection classification, in-line wrist 13Protection classification, robot 13Protective equipment, overview 76Purpose 7RReaction distance 6, 73Recommissioning 80Reference point 13Relative air humidity 15Release device 77Repair 82Repeatability 13Robot 9Robot controller 9, 71Robot system 9Rotating column 9, 11SSafety 71Safety instructions 5Safety zone 73, 75, 76Safety, general 71Service life 73Service, KUKA Roboter 97smartPAD 6, 9, 73, 78Software 9, 71Sound level 13Start-up 80STOP 0 38, 73STOP 1 38, 73STOP 2 73Stop category 0 73Stop category 1 73Stop category 2 73Stop signal 38Stopping distance 6, 38, 73, 76Stopping distances 38Stopping distances, KR 360 L240-3 44Stopping distances, KR 360 L240-3 F 44Stopping distances, KR 360 L280-3 49Stopping distances, KR 360 L280-3 F 49Stopping distances, KR 360-3 39Stopping distances, KR 360-3 F 39Stopping distances, KR 500 L340-3 59Stopping distances, KR 500 L340-3 F 59Stopping distances, KR 500 L420-3 64Stopping distances, KR 500 L420-3 C 64Stopping distances, KR 500 L420-3 F 64Stopping distances, KR 500-3 54Stopping distances, KR 500-3 C 54Stopping distances, KR 500-3 F 54Stopping time 38Stopping times 38Stopping times, KR 360 L240-3 44Stopping times, KR 360 L240-3 F 44Stopping times, KR 360 L280-3 49Stopping times, KR 360 L280-3 F 49Stopping times, KR 360-3 39Stopping times, KR 360-3 F 39Stopping times, KR 500 L340-3 59Stopping times, KR 500 L340-3 F 59Stopping times, KR 500 L420-3 64Stopping times, KR 500 L420-3 C 64Stopping times, KR 500 L420-3 F 64Stopping times, KR 500-3 54Stopping times, KR 500-3 C 54Stopping times, KR 500-3 F 54Storage 83Supplementary load 32Support request 97Surface finish, paintwork 13Swing frame 10System integrator 72, 73, 74TT1 73T2 74Teach pendant 9, 71Technical data 13Terms used 6, 38Terms used, safety 73Training 7Transportation 79, 93Transportation by fork lift truck 95Transportation with lifting tackle 95Turn-tilt table 71UUse, contrary to intended use 71Use, improper 71User 73, 74Users 7106 / 109 Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)

IndexVVolume of working envelope 13WWarnings 5Weight 13Working envelope 18Working range limitation 76Workspace 73, 75, 76Wrist 10Issued: 22.07.2013 Version: Spez KR 360-3 KR 500-3 V5 en (PDF)107 / 109

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