KR 16 arc HW, KR 16 L8 arc HW - KUKA Robotics
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Robots<strong>KUKA</strong> Roboter GmbH<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>SpecificationIssued: 19.04.2013Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>© Copyright 2013<strong>KUKA</strong> Roboter GmbHZugspitzstraße 140D-86<strong>16</strong>5 AugsburgGermanyThis documentation or excerpts therefrom may not be reproduced or disclosed to third parties withoutthe express permission of <strong>KUKA</strong> 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 <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> enBookstructure: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V7.1Version:Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)2 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

ContentsContents1 Introduction .................................................................................................. 51.1 Industrial robot documentation ................................................................................... 51.2 Representation of warnings and notes ...................................................................... 52 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 .................................................................................................................... 144.3 Payloads .................................................................................................................... 174.4 Loads acting on the mounting base ........................................................................... 234.5 Transport dimensions ................................................................................................ 244.6 Plates and labels ........................................................................................................ 274.7 Stopping distances and times, <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> ........................................................... 294.7.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 ................... 294.7.2 Stopping distances and stopping times for STOP 1, axis 1 .................................. 304.7.3 Stopping distances and stopping times for STOP 1, axis 2 .................................. 324.7.4 Stopping distances and stopping times for STOP 1, axis 3 .................................. 344.8 Stopping distances and times, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong> ...................................................... 344.8.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 ................... 344.8.2 Stopping distances and stopping times for STOP 1, axis 1 .................................. 354.8.3 Stopping distances and stopping times for STOP 1, axis 2 .................................. 374.8.4 Stopping distances and stopping times for STOP 1, axis 3 .................................. 395 Safety ............................................................................................................ 415.1 General ...................................................................................................................... 415.1.1 Liability .................................................................................................................. 415.1.2 Intended use of the industrial robot ...................................................................... 425.1.3 EC declaration of conformity and declaration of incorporation ............................. 425.1.4 Terms used ........................................................................................................... 435.2 Personnel ................................................................................................................... 445.3 Workspace, safety zone and danger zone ................................................................. 455.4 Overview of protective equipment .............................................................................. 465.4.1 Mechanical end stops ........................................................................................... 465.4.2 Mechanical axis range limitation (optional) ........................................................... 465.4.3 Axis range monitoring (optional) ........................................................................... 475.4.4 Options for moving the manipulator without the robot controller .......................... 475.4.5 Labeling on the industrial robot ............................................................................. 485.5 Safety measures ........................................................................................................ 495.5.1 General safety measures ...................................................................................... 495.5.2 Transportation ....................................................................................................... 505.5.3 Start-up and recommissioning .............................................................................. 50Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)3 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>5.5.4 Manual mode ........................................................................................................ 515.5.5 Automatic mode ................................................................................................... 525.5.6 Maintenance and repair ........................................................................................ 525.5.7 Decommissioning, storage and disposal .............................................................. 545.6 Applied norms and regulations .................................................................................. 546 Planning ........................................................................................................ 576.1 Mounting base with centering .................................................................................... 576.2 Machine frame mounting with centering .................................................................... 596.3 Adapter plate ............................................................................................................. 606.4 Connecting cables and interfaces ............................................................................. 617 Transportation ............................................................................................. 637.1 Transporting the robot ............................................................................................... 638 <strong>KUKA</strong> Service ............................................................................................... 698.1 Requesting support ................................................................................................... 698.2 <strong>KUKA</strong> Customer Support ........................................................................................... 69Index ............................................................................................................. 774 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 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 <strong>KUKA</strong> 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: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)5 / 79

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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 <strong>KUKA</strong> 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: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)7 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>8 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

3 Product description3 Product description3.1 Overview of the robot systemA robot system (>>> Fig. 3-1 ) comprises all the assemblies of an industrialrobot, including the manipulator (mechanical system and electrical installations),control cabinet, connecting cables, end effector (tool) and other equipment.The industrial robots <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> and <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong> comprise thefollowing components:• Manipulator• Robot controller• Connecting cables• KCP teach pendant• Software• Options, accessoriesFig. 3-1: Example of a robot system1 Manipulator 3 Robot controller2 Connecting cables 4 Teach pendant (KCP)SafeRobotRoboTeamThe SafeRobot option is available for this robot.In this case the robot moves within limits that have been configured. The actualposition is continuously calculated and monitored by the SafeRDC. If therobot violates a monitoring limit or a safety parameter, it is stopped.The RoboTeam option is available for this robot.RoboTeam allows the operation of cooperating robot systems. In the RoboTeam,up to 15 robots can work together in a group. One robot in the group alwaystakes on the role of “master”, while the remaining robots work as“slaves”.3.2 Description of the robotOverviewThese manipulators (robots) (>>> Fig. 3-2 ) are designed as a 6-axis jointedarmkinematic system. They consist of the following principal components:Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)9 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>• Hollow-shaft wrist• Arm• Link arm• Rotating column• Base frame• Electrical installationsFig. 3-2: Main assemblies of the manipulator1 Hollow-shaft wrist 4 Base frame2 Arm 5 Rotating column3 Electrical installations 6 Link armHollow-shaftwristArmLink armRotating columnThe robot variants <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> and <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong> are equipped with a2-axis hollow-shaft wrist. The wrist contains axes 5 and 6. The motors of axes5 and 6 are incorporated in this assembly. Both axes are driven via toothedbelts and gear units. The design enables the fluid supply to be routed directlythrough the center of axis 6 to the application.For attaching end effectors (tools), the in-line wrist has a mounting flange.The arm is the link between the hollow-shaft wrist and the link arm. It housesthe motors of wrist axes 3 and 4. The arm is driven by the motor of axis 3. Themaximum permissible swivel angle is mechanically limited by a stop for eachdirection, plus and minus. The associated buffers are attached to the link arm.The entire drive unit of axis 4 is also integrated inside the arm. In addition, thecable harness for the wrist axes A 5 and A 6 is installed under a cover. Fasteningfacilities are provided for the welding application equipment on the rearof the arm. The fluid supply to the tool is routed axially through the arm.The link arm is the assembly located between the arm and the rotating column.It consists of the link arm body with the buffers.The rotating column houses the motors of axes 1 and 2. The rotational motionof axis 1 is performed by the rotating column. This is screwed to the baseframe via the gear unit of axis 1 and is driven by a motor in the rotating column.The link arm is also mounted in the rotating column.10 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

3 Product descriptionBase frameElectrical installationsThe base frame is the base of the robot. It is screwed to the mounting base.The flexible tube for the electrical installations is fastened to the base frame.Also located on the base frame is the multi-function housing (MFH) and thedata cable junction box.The electrical installations include all the motor and control cables for the motorsof axes 1 to 6. All connections are implemented as connectors in order toenable the motors to be exchanged quickly and reliably. The electrical installationsalso include the RDC box and the multi-function housing (MFH), bothof which are mounted on the robot base frame. The connecting cables fromthe robot controller are connected to these junction boxes by means of connectors.The electrical installations also include a protective circuit.For the supply to the wrist axis drives, an additional cable harness is integratedinto the arm, which ensures that the cables are guided without kinking throughoutthe motion range of axis 4.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)11 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>12 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical data4 Technical data4.1 Basic dataBasic dataType<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong><strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Number of axes 6Volume of working envelope<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>: 15.44 m 3<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>: 29.22 m 3Pose repeatability(ISO 9283)Working envelope referencepointWeightPrincipal dynamic loads<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>: ±0.04 mm<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>: ±0.04 mmIntersection of axes 4 and 5<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>: 245 kg<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>: 240 kgSee “Loads acting on the mounting base”Protection classificationof the robotProtection classificationof the in-line wristSound levelMounting positionSurface finish, paintworkIP 54ready for operation, with connecting cablesplugged in (according to EN 60529)IP 54< 75 dB (A) outside the working envelopeFloor, ceilingBase frame, covers on hollow-shaft wrist andarm: black (RAL 9005); moving parts: <strong>KUKA</strong>orange 2567Ambient temperatureOperationOperation with SafeRDCStorage and transportation283 K to 328 K (+10 °C to +55 °C)283 K to 323 K (+10 °C to +50 °C)233 K to 333 K (-40 °C to +60 °C)Start-up283 K to 288 K (+10 °C to +15 °C)At these temperatures the robot may have to bewarmed up before normal operation. Other temperaturelimits available on request.Humidity rating DIN EN 60721-3-3,Class 3K3The maintenance intervals and the specified service life are based on typicalgear unit temperatures and axis motions. If special functions or applicationsresult in atypical gear unit temperatures or axis motions, this can lead to increasedwear. In this case, the maintenance intervals or service life may beshortened. If you have any questions, please contact <strong>KUKA</strong> Customer Support.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)13 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>ConnectingcablesCable designationConnector designationrobot controller - robotInterface with robotMotor cable X20 - X30 Harting connectors atboth endsData cable X21 - X31 Harting connectors atboth endsData cable, SafeRobot X21.1 - X41 Harting connectors atboth endsCable lengthsStandardWith RoboTeam*With SafeRobot*7 m, 15 m, 25 m, 35 m, 50 m7 m, 15 m, 25 m, 35 m7 m, 15 m, 25 m, 35 m* Only with <strong>KR</strong> C2.For detailed specifications of the connecting cables, see “Description of theconnecting cables” (>>> 6.4 "Connecting cables and interfaces" Page 61).4.2 Axis dataAxis dataThe following data are valid for the robot <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>:AxisRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 200 °/s2 +35° to -155° 200 °/s3 +154° to -120° 195 °/s4 +/-<strong>16</strong>5° 370 °/s5 +/-130° 310 °/s6 Infinitely rotating 610 °/sThe following data are valid for the robot <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>:AxisRange of motion, softwarelimitedSpeed withrated payload1 +/-185° 127 °/s2 +35° to -155° 130 °/s3 +154° to -120° 125 °/s4 +/-<strong>16</strong>5° 315 °/s5 +/-140° 320 °/s6 Infinitely rotating 680 °/sThe direction of motion and the arrangement of the individual axes may be notedfrom the following diagram.14 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataFig. 4-1: Direction of rotation of the axesWorkingenvelopeThe following diagrams show the shape and size of the working envelopes forthe robots <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> (>>> Fig. 4-2 ) and <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong> (>>> Fig. 4-3 ).The reference point for the working envelope is the intersection of axes 4 and5.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)15 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-2: Working envelope, <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong><strong>16</strong> / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataFig. 4-3: Working envelope for <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>4.3 PayloadsPayloads<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>RobotIn-line wristRated payloadDistance of the load center of gravity L z (horizontal)<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>IW <strong>16</strong> <strong>arc</strong> <strong>HW</strong><strong>16</strong> kg120 mmIssued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)17 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Robot<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>Distance of the load center of gravity L xy (vertical) 80 mmPermissible mass moment of inertia 0.36 kgm 2Max. total load48 kgSupplementary load, arm12 kgSupplementary load, link armNoneSupplementary load, rotating column20 kgSupplementary load, base frameNonePayloads<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Load center ofgravity PRobot<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>In-line wristIW 5 <strong>arc</strong> <strong>HW</strong>Rated payload8 kgDistance of the load center of gravity L z (horizontal) 70 mmDistance of the load center of gravity L xy (vertical) 50 mmPermissible mass moment of inertia 0.10 kgm 2Max. total loadSupplementary load, armSupplementary load, link armSupplementary load, rotating columnSupplementary load, base frame40 kg12 kgNone20 kgNoneFor 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.18 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataPayload diagramFig. 4-4: Payload diagram, <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)19 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-5: Payload diagram, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>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 <strong>KUKA</strong> 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 <strong>KUKA</strong> SystemSoftware.The mass inertia must be verified using <strong>KUKA</strong>.Load. It is imperative for theload data to be entered in the robot controller!Mounting flangeRobot <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Wrist IW <strong>16</strong> <strong>arc</strong> <strong>HW</strong> IW 5 <strong>arc</strong> <strong>HW</strong>Mounting flange (hole circle) 66 mm 58 mmScrew grade 10.9 10.9Screw size M5 M4Grip length1.5 x nominaldiameter1.5 x nominaldiameterDepth of engagementmin. 7 mm,max. 8 mmLocating element 5 H7 4 H7min. 6 mm,max. 7 mm20 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataThe mounting flange is depicted with axes 4 and 6 in the zero position. Thesymbol X m indicates the position of the locating element (bushing) in the zeroposition.Fig. 4-6: Mounting flange, <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)21 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-7: Mounting flange, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Interface A6 The hollow-shaft wrists are provided with a special interface, interface A6,which allows welding equipment to be connected to the swivel housing. Thedimensions and designs of this interface can be seen in the following illustrations.Fig. 4-8: Interface A6, IW <strong>16</strong> <strong>arc</strong> <strong>HW</strong>22 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataFig. 4-9: Interface A6, IW 5 (8 kg) <strong>arc</strong> <strong>HW</strong>SupplementaryloadThe robot can carry supplementary loads on the arm. When mounting the supplementaryloads, be careful to observe the maximum permissible total load.The dimensions and positions of the installation options can be seen in the followingdiagram. These dimensions and positions are valid for <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>and <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>.Fig. 4-10: Supplementary load on arm (example: <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>)4.4 Loads acting on the mounting baseLoads acting onthe mountingbaseThe specified forces and moments already include the payload and the inertiaforce (weight) of the robot.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)23 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-11: Loads acting on the mounting baseType of loadF v = vertical forceF h = horizontal forceM k = tilting momentM r = torqueTotal mass for load acting on the mountingbaseRobotTotal load (suppl. load on arm + rated payload)Force/torque/massF vmax = 4,600 NF hmax = 5,000 NM kmax = 5,200 NmM rmax = 4,200 Nm<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>: 273 kg<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>: 258 kg<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>: 245 kg<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>: 240 kg<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>: 28 kg<strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>: 20 kgThe supplementary loads on the base frame and rotating column are not takeninto consideration in the calculation of the mounting base load. These supplementaryloads must be taken into consideration for F v .4.5 Transport dimensionsThe transport dimensions (>>> Fig. 4-12 ) for the robot can be noted from thefollowing diagram. The position of the center of mass and the weight vary accordingto the specific configuration. The specified dimensions refer to the robotwithout equipment. The following diagram shows the dimensions of therobot when it stands on the floor without wooden transport blocks.24 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataFig. 4-12: Transport dimensions, floor-mounted robot <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>1 Robot 2 Center of gravityFig. 4-13: Transport dimensions, floor-mounted robot <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>1 Robot 2 Center of gravityFor transporting ceiling-mounted robots in the mounting position, a transportframe is provided (>>> Fig. 4-14 ), which can be picked up using a crane attachedto 4 eyebolts, or with a fork lift truck.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)25 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-14: Transport dimensions, ceiling-mounted robot <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>1 Robot2 Center of gravity3 Eyebolts4 Fork slots5 Transport frame for ceiling-mounted robot26 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataFig. 4-15: Transport dimensions, ceiling-mounted robot <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>1 Robot2 Center of gravity3 Eyebolts4 Fork slots5 Transport frame for ceiling-mounted robot4.6 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.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)27 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-<strong>16</strong>: Plates and labels28 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical data4.7 Stopping distances and times, <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>4.7.1 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 42.<strong>16</strong> 0.387Axis 2 41.35 0.385Axis 3 33.51 0.266Stopping time (s)Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)29 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>4.7.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-17: Stopping distances for STOP 1, axis 130 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataFig. 4-18: Stopping times for STOP 1, axis 1Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)31 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>4.7.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-19: Stopping distances for STOP 1, axis 232 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical dataFig. 4-20: Stopping times for STOP 1, axis 2Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)33 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>4.7.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-21: Stopping distances for STOP 1, axis 3Fig. 4-22: Stopping times for STOP 1, axis 34.8 Stopping distances and times, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>4.8.1 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 30.49 0.343Axis 2 31.00 0.324Axis 3 23.70 0.271Stopping time (s)34 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical data4.8.2 Stopping distances and stopping times for STOP 1, axis 1Fig. 4-23: Stopping distances for STOP 1, axis 1Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)35 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-24: Stopping times for STOP 1, axis 136 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical data4.8.3 Stopping distances and stopping times for STOP 1, axis 2Fig. 4-25: Stopping distances for STOP 1, axis 2Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)37 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 4-26: Stopping times for STOP 1, axis 238 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

4 Technical data4.8.4 Stopping distances and stopping times for STOP 1, axis 3Fig. 4-27: Stopping distances for STOP 1, axis 3Fig. 4-28: Stopping times for STOP 1, axis 3Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)39 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>40 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 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 <strong>KUKA</strong> 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 <strong>KUKA</strong> 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 <strong>KUKA</strong> Roboter GmbH. Additional components (tools, software,etc.), not supplied by <strong>KUKA</strong> 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: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)41 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>5.1.2 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 machinery42 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 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 lifeKCP<strong>KUKA</strong> smartPADManipulatorSafety zoneStop category 0Stop category 1Stop category 2System integrator(plant integrator)T1T2External axisDescriptionRange 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.The KCP (<strong>KUKA</strong> Control Panel) teach pendant has all the operator controland display functions required for operating and programming theindustrial robot.The KCP variant for the <strong>KR</strong> C4 is called <strong>KUKA</strong> smartPAD. The generalterm “KCP”, however, is generally used in this documentation.See KCPThe robot arm and the associated electrical installationsThe safety zone is situated outside the danger zone.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 ( 250 mm/s permissible)Motion axis which is not part of the manipulator but which is controlledusing the robot controller, e.g. <strong>KUKA</strong> linear unit, turn-tilt table, Posiflex.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)43 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>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 integratorOperatorExampleThe 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.The tasks can be distributed as shown in the following table.44 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

5 SafetyTasks 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: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)45 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 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 <strong>KUKA</strong> Roboter GmbH must be consulted beforeit is put back into operation (>>> 8 "<strong>KUKA</strong> Service" Page 69).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.46 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 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 <strong>KUKA</strong> Roboter GmbH.5.4.3 Axis range monitoring (optional)Some manipulators can be fitted with dual-channel axis range monitoring systemsin main axes A1 to A3. The positioner axes may be fitted with additionalaxis range monitoring systems. The safety zone for an axis can be adjustedand monitored using an axis range monitoring system. This increases personalsafety and protection of the system.This option is not available for all robot models. Information on specificrobot models can be obtained from <strong>KUKA</strong> Roboter GmbH.5.4.4 Options for moving the manipulator without the robot controllerDescriptionThe following options are available for moving the manipulator after an accidentor 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 handIn the case of the low payload category, no release device for the wristaxes is available. A release device is not necessary, as the wrist axes canbe moved directly by hand.The options are only for use in exceptional circumstances and emergencies,e.g. for freeing people.Information on the availability of options for specific robot models canbe obtained from <strong>KUKA</strong> Roboter GmbH.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.ProcedureMoving the manipulator with the release device:The following procedure must be followed exactly!1. Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized persons from switching it on again.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)47 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>2. Remove the protective cap from the motor.3. Push the release device onto the corresponding motor and move the axisin the desired direction.The directions are indicated with arrows on the motors. It is necessary toovercome the resistance of the mechanical motor brake and any otherloads acting on the axis.Moving an axis with the release device can damage themotor brake. This can result in personal injury and materialdamage. After using the release device, the motor must be exchanged.If a robot axis has been moved by the release device, allrobot axes must be remastered. Serious infuries or damageto property may otherwise result.ProcedureMoving the manipulator with the brake release device:Use of the brake release device may result in unexpectedrobot motions, especially sagging of the axes. Duringuse of the brake release device, attention must be paid to motion of this kindin order to be able to prevent physical injuries or damage to property. Standingunder moving axes is not permitted.The following procedure must be followed exactly!1. Switch off the robot controller and secure it (e.g. with a padlock) to preventunauthorized persons from switching it on again.2. Connect the brake release device to the base frame of the robot:Unplug connector X30 from interface A1. Plug connector X20 of the brakerelease device into interface A1.3. Select the brakes to be released (main axes, wrist axes) via the selectionswitch on the brake release device.4. Press the button on the hand-held device.The brakes of the main axes or wrist axes are released and the robot canbe moved manually.Further information about the brake release device can be found inthe documentation for the brake release device.5.4.5 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.48 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

5 Safety5.5 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. Incorrect installation(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.KCPThe user must ensure that the industrial robot is only operated with the KCPby authorized persons.If more than one KCP is used in the overall system, it must be ensured thateach KCP is unambiguously assigned to the corresponding industrial robot.They must not be interchanged.The operator must ensure that decoupled KCPs are immediatelyremoved from the system and stored out ofsight and reach of personnel working on the industrial robot. This serves toprevent operational and non-operational EMERGENCY STOP devices frombecoming 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 must not be used as long as an external keyboard and/or externalmouse 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 is connected.FaultsThe following tasks must be carried out in the case of faults in the industrialrobot:Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)49 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>• 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.ModificationsAfter 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.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. <strong>KUKA</strong> 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.5.5.3 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 <strong>KUKA</strong> 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.50 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

5 SafetyIf additional components (e.g. cables), which are not part of the scopeof supply of <strong>KUKA</strong> 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.5.5.4 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.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)51 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>• 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.If 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.52 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

5 Safety• 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 <strong>KR</strong> C4 or V<strong>KR</strong> 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 <strong>KUKA</strong> Roboter GmbHfor this purpose.Cleaning and preventive maintenance work is to be carried out in accordancewith the operating instructions.Robot controllerCounterbalancingsystemEven 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 preventlife-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.Some 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.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)53 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>• Work on the counterbalancing systems must only be carried out by qualifiedpersonnel.HazardoussubstancesThe 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/<strong>16</strong>/EC (recast)20062004/108/EC97/23/ECEN ISO 13850EN ISO 13849-1EN ISO 13849-2EN ISO 12100EN ISO 10218-1EMC 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/EECPressure 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:Safety200419972008200820082010201154 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

5 SafetyName Definition EditionEN 614-1EN 61000-6-2EN 61000-6-4EN 60204-1Safety 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: Generalrequirements2006200520072006Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)55 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>56 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

6 Planning6 Planning6.1 Mounting base with centeringDescriptionThe mounting base with centering is used when the robot is fastened to thefloor, i.e. directly on a concrete foundation. There are two variants available,which differ in their construction and method of installation. The installation dimensionson the concrete foundation and the interface dimensions for the robotare identical, however.• Variant 1: Mounting base with centering (resin capsule)• Variant 2: Mounting base with centering (resin cartridge)Both mounting base variants consist of:• Bedplates• Resin-bonded anchors• FastenersThese mounting variants require a level and smooth surface on a concretefoundation with adequate load bearing capacity.Fig. 6-1: Mounting base with centering1 Locating pin for centering2 Hexagon bolt3 Bedplate4 Resin-bonded anchorGrade 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 (>>> Fig. 6-2 ) provides all the necessary informationon the mounting base, together with the required foundation data.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)57 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 6-2: Mounting base with centering, dimensioned drawing1 Hexagon bolts2 Locating pin3 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 foundations58 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

6 Planning1 Anchor 4 Bedplate2 Locating pin 5 Concrete foundation3 Hexagon bolt6.2 Machine frame mounting with centeringDescriptionThe machine frame mounting (>>> Fig. 6-4 ) with centering is used for installingthe robot on a steel structure provided by the customer or on a carriage ofa <strong>KUKA</strong> linear unit. The mounting surface for the robot must be machined andof an appropriate quality. The robot is fastened to the machine frame mountingoption using 3 hexagon bolts. Two locating pins are used for centering.The machine frame mounting assembly consists of:• Locating pins• Hexagon bolts with conical spring washersFig. 6-4: Machine frame mounting1 Mounting surface2 Locating pin3 Hexagon bolt with conical spring washerDimensioneddrawingThe following illustrations provide all the necessary information on machineframe mounting, together with the required foundation data.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)59 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 6-5: Machine frame mounting, dimensioned drawing1 Locating pin2 Hexagon bolt3 Mounting surface, machined6.3 Adapter plateDescriptionThe adapter plate enables the robot to be fastened to• mounting bases• steel structures• carriages of <strong>KUKA</strong> linear unitswhich are already equipped with the hole pattern for the <strong>KR</strong> 6.The mounting surface for the adapter plate (>>> Fig. 6-6 ) must be machinedand of an appropriate quality. The adapter plate is fastened to the mountingbase with the <strong>KR</strong> 6 hole pattern with 3 Allen screws. 2 pins are used for centering.For fastening the robot to the adapter platte, the “machine frame mounting”assembly with 3 hexagon bolts is required, together with 2 locating pinsfor centering.60 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

6 PlanningFig. 6-6: Adapter plate1 Fastening hole2 Adapter plateThe size and dimensions of the adapter plate (>>> Fig. 6-7 ) are given in thefollowing diagram.Fig. 6-7: Adapter plate6.4 Connecting cables and interfacesThe 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.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)61 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>• 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.Fig. 6-8: Connecting cables and interfaces1 Interface A3, arm2 Interface A6, tool3 Junction box, control cable X312nd control cable X41 (for SafeRobot only)4 Interface A1, energy supply system5 Connection, motor cable X3062 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

7 Transportation7 Transportation7.1 Transporting the robotMove the robot into its transport position (>>> Fig. 7-1 ) each time it is transported.It must be ensured that the robot is stable while it is being transported.The robot must remain in its transport position until it has been fastened in position.Before the robot is lifted, it must be ensured that it is free from obstructions.Remove all transport safeguards, such as nails and screws, in advance.First remove any rust or glue on contact surfaces.TransportpositionThe transport position is the same for both floor-mounted and ceiling-mountedrobots. The robot is in the transport position when the axes are in the followingpositions:Axis A1 A2 A3 A4 A5 A6Angle 0º -155º +154º 0º +100º 0ºFig. 7-1: Transport positionTransport dimensionsThe transport dimensions for the robot can be noted from the following figures.The position of the center of mass and the weight vary according to the specificconfiguration. The specified dimensions refer to the robot without equipment.Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)63 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 7-2: Transport dimensions, floor-mounted robot <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>1 Robot 2 Center of gravityFig. 7-3: Transport dimensions, floor-mounted robot <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>1 Robot 2 Center of gravityCeiling-mounted robots can also be transported in a transport frame, alreadyin the correct orientation. The transport frame can be picked up with a fork lifttruck via the fork slots, or with a crane via eyebolts.64 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

7 TransportationFig. 7-4: Transport dimensions, ceiling-mounted robot <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>1 Robot2 Center of gravity3 Eyebolts4 Fork slots5 Transport frame for ceiling-mounted robotIssued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)65 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Fig. 7-5: Transport dimensions, ceiling-mounted robot <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>1 Robot2 Center of gravity3 Eyebolts4 Fork slots5 Transport frame for ceiling-mounted robotTransportationThe floor-mounted robot is transported using lifting tackle or via the fork slots.Without the transport frame, ceiling-mounted robots can only be transportedin mounting position by fork lift truck. In the transport frame, transportation withfork lift truck or crane is possible.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.Transportation byfork lift truckThe ceiling-mounted robot is transported using a fork lift truck (>>> Fig. 7-6 ).For transport by fork lift truck, the fork slots must be installed. The robot mustbe in the transport position for ceiling installation.66 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

7 TransportationFig. 7-6: Transportation by fork lift truckTransportationusing liftingtackleThe floor-mounted robot is transported using lifting tackle (>>> Fig. 7-7 ). Therobot must be in the transport position. The lifting tackle is attached to 3 eyeboltsthat are screwed into the rotating column. All ropes of the lifting tacklemust be long enough and must be routed in such a way that the robot is notdamaged. Installed tools and pieces of equipment can cause undesirableshifts in the center of gravity. These must therefore be removed if necessary.The eyebolt must be removed from the rotating column after transportation.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!Fig. 7-7: Lifting tackle1 Crane 4 Fork slots2 Lifting tackle 5 Eyebolt3 Transport frameIssued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)67 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>68 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

8 <strong>KUKA</strong> Service8 <strong>KUKA</strong> Service8.1 Requesting supportIntroductionInformationThe <strong>KUKA</strong> Roboter GmbH documentation offers information on operation andprovides assistance with troubleshooting. For further assistance, please contactyour local <strong>KUKA</strong> subsidiary.The following information is required for processing a support request:• Model and serial number of the robot• 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 <strong>KUKA</strong> System Software• Optional software or modifications• Archive of the softwareFor <strong>KUKA</strong> System Software V8: instead of a conventional <strong>arc</strong>hive, generatethe special data package for fault analysis (via KrcDiag).• Application used• Any external axes used• Description of the problem, duration and frequency of the fault8.2 <strong>KUKA</strong> Customer SupportAvailability<strong>KUKA</strong> 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: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)69 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Belgium<strong>KUKA</strong> Automatisering + Robots N.V.Centrum Zuid 10313530 HouthalenBelgiumTel. +32 11 5<strong>16</strong><strong>16</strong>0Fax +32 11 526794info@kuka.bewww.kuka.beBrazil<strong>KUKA</strong> 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.clChina<strong>KUKA</strong> <strong>Robotics</strong> China Co.,Ltd.Songjiang Industrial ZoneNo. 388 Minshen Road20<strong>16</strong>12 ShanghaiChinaTel. +86 21 6787-1888Fax +86 21 6787-1803www.kuka-robotics.cnGermany<strong>KUKA</strong> Roboter GmbHZugspitzstr. 14086<strong>16</strong>5 AugsburgGermanyTel. +49 821 797-4000Fax +49 821 797-<strong>16</strong><strong>16</strong>info@kuka-roboter.dewww.kuka-roboter.de70 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

8 <strong>KUKA</strong> ServiceFrance<strong>KUKA</strong> Automatisme + Robotique SASTechvallée6, Avenue du P<strong>arc</strong>91140 Villebon S/YvetteFranceTel. +33 1 693<strong>16</strong>60-0Fax +33 1 693<strong>16</strong>60-1commercial@kuka.frwww.kuka.frIndia<strong>KUKA</strong> <strong>Robotics</strong> 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.inItaly<strong>KUKA</strong> 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.itJapan<strong>KUKA</strong> <strong>Robotics</strong> Japan K.K.YBP Technical Center134 Godo-cho, Hodogaya-kuYokohama, Kanagawa240 0005JapanTel. +81 45 744 7691Fax +81 45 744 7696info@kuka.co.jpCanada<strong>KUKA</strong> <strong>Robotics</strong> Canada Ltd.6710 Maritz Drive - Unit 4MississaugaL5W 0A1OntarioCanadaTel. +1 905 670-8600Fax +1 905 670-8604info@kukarobotics.comwww.kuka-robotics.com/canadaIssued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)71 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Korea<strong>KUKA</strong> <strong>Robotics</strong> 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.comMalaysia<strong>KUKA</strong> 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.myMexico<strong>KUKA</strong> 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/mexicoNorway<strong>KUKA</strong> Sveiseanlegg + RoboterSentrumsvegen 52867 HovNorwayTel. +47 61 18 91 30Fax +47 61 18 62 00info@kuka.noAustria<strong>KUKA</strong> Roboter Austria GmbHVertriebsbüro ÖsterreichRegensburger Strasse 9/14020 LinzAustriaTel. +43 732 784752Fax +43 732 793880office@kuka-roboter.atwww.kuka-roboter.at72 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

8 <strong>KUKA</strong> ServicePoland<strong>KUKA</strong> 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.dePortugal<strong>KUKA</strong> Sistemas de Automatización S.A.Rua do Alto da Guerra n° 50Armazém 042910 011 SetúbalPortugalTel. +351 265 729780Fax +351 265 729782kuka@mail.telepac.ptRussiaOOO <strong>KUKA</strong> <strong>Robotics</strong> RusWebnaja ul. 8A107143 MoskauRussiaTel. +7 495 781-31-20Fax +7 495 781-31-19kuka-robotics.ruSweden<strong>KUKA</strong> Svetsanläggningar + Robotar ABA. Odhners gata 15421 30 Västra FrölundaSwedenTel. +46 31 7266-200Fax +46 31 7266-201info@kuka.seSwitzerland<strong>KUKA</strong> Roboter Schweiz AGIndustriestr. 95432 NeuenhofSwitzerlandTel. +41 44 74490-90Fax +41 44 74490-91info@kuka-roboter.chwww.kuka-roboter.chIssued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)73 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Spain<strong>KUKA</strong> Robots IBÉRICA, S.A.Pol. IndustrialTorrent de la PasteraCarrer del Bages s/n08800 Vilanova i la Geltrú (B<strong>arc</strong>elona)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.zaTaiwan<strong>KUKA</strong> 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.twThailand<strong>KUKA</strong> 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 Republic<strong>KUKA</strong> 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.cz74 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

8 <strong>KUKA</strong> ServiceHungary<strong>KUKA</strong> <strong>Robotics</strong> Hungaria Kft.Fö út 1402335 TaksonyHungaryTel. +36 24 50<strong>16</strong>09Fax +36 24 477031info@kuka-robotics.huUSA<strong>KUKA</strong> <strong>Robotics</strong> Corporation51870 Shelby ParkwayShelby Township48315-1787MichiganUSATel. +1 866 873-5852Fax +1 866 329-5852info@kukarobotics.comwww.kukarobotics.comUK<strong>KUKA</strong> Automation + <strong>Robotics</strong>Hereward RiseHalesowenB62 8ANUKTel. +44 121 585-0800Fax +44 121 585-0900sales@kuka.co.ukIssued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)75 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>76 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

IndexIndexNumbers2004/108/EC 542006/42/EC 5489/336/EEC 5495/<strong>16</strong>/EC 5497/23/EC 54AAccessories 9, 41Adapter plate 60Ambient temperature, operation 13Ambient temperature, operation, Safe RDC 13Ambient temperature, start-up 13Ambient temperature, storage 13Ambient temperature, transportation 13Applied norms and regulations 54Arm 10Automatic mode 52Axes, number 13Axis data 14Axis range 43Axis range limitation 46Axis range monitoring 47BBase frame 10, 11Basic data 13Brake defect 49Brake release device 47Braking distance 43CCE mark 42Center of gravity 24, 63Cleaning work 53Connecting cables 9, 14, 41, 61Connecting cables, cable lengths 14Counterbalancing system 53DDanger zone 43Declaration of conformity 42Declaration of incorporation 41, 42Decommissioning 54Description of the robot system 9Dimensions, transport 24, 63Disposal 54Documentation, industrial robot 5EEC declaration of conformity 42Electrical installations 10, 11EMC Directive 42, 54EN 60204-1 55EN 61000-6-2 55EN 61000-6-4 55EN 614-1 55EN ISO 10218-1 54EN ISO 12100 54EN ISO 13849-1 54EN ISO 13849-2 54EN ISO 13850 54External axes 41, 43FFaults 49Fork lift truck 66Function test 51GGear unit temperatures 13General safety measures 49HHandling equipment 66Hazardous substances 54Hollow-shaft wrist 10Humidity rating 13IIndustrial robot 41Intended use 42Interface A6 22Interface, energy supply systems 62Interfaces 61Introduction 5ISO 9283, repeatability 13KKCP 9, 43, 49Keyboard, external 49<strong>KUKA</strong> Customer Support 69<strong>KUKA</strong> smartPAD 43LLabeling 48Liability 41Lifting tackle 66, 67Linear unit 41Link arm 10Loads acting on the mounting base 23Low Voltage Directive 42MMachine data 51Machine frame mounting with centering 59Machinery Directive 42, 54Maintenance 52Manipulator 9, 41, 43, 46Manual mode 51Mechanical axis range limitation 46Mechanical end stops 46Mounting base with centering 57Mounting flange 10, 20Mounting position 13Mouse, external 49Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)77 / 79

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>OOperator 43, 44Options 9, 41Overload 49PPayload diagram 19Payloads, <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> 17Payloads, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong> 18Personnel 44Plant integrator 43Plates and labels 27Positioner 41Pressure Equipment Directive 53, 54Preventive maintenance work 53Principal components 9Principal loads, dynamic 13Product description 9Protection classification, in-line wrist 13Protection classification, robot 13Protective equipment, overview 46Purpose 7RReaction distance 43Recommissioning 50Reference point 13Relative air humidity 13Release device 47Repair 52Repeatability 13Robot controller 9, 41Robot system 9Rotating column 10TT1 43T2 43Teach pendant 9, 41Technical data 13Terms used, safety 43Training 7Transport dimensions 24Transport position 63Transportation 50, 63Turn-tilt table 41UUse, contrary to intended use 41Use, improper 41User 43, 44Users 7VVolume of working envelope 13WWarnings 5Weight 13Working range limitation 46Workspace 43, 45, 46SSafety 41Safety instructions 5Safety zone 43, 45, 46Safety, general 41Service life 43Service, <strong>KUKA</strong> Roboter 69smartPAD 43Software 9, 41Sound level 13Start-up 50STOP 0 43STOP 1 43STOP 2 43Stop category 0 43Stop category 1 43Stop category 2 43Stopping distance 43, 46Stopping distances 29, 34Stopping times 29, 34Storage 54Supplementary load 23Support request 69Surface finish, paintwork 13System integrator 42, 43, 4478 / 79 Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)

<strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong>, <strong>KR</strong> <strong>16</strong> <strong>L8</strong> <strong>arc</strong> <strong>HW</strong>Issued: 19.04.2013 Version: Spez <strong>KR</strong> <strong>16</strong> <strong>arc</strong> <strong>HW</strong> V6 en (PDF)79 / 79

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