Manual Posicionadores KP1-H

Positioner KP1-H-2; KP1-HC-2 Assembly Instructions Issued: 10.10.2022 MA KP1-H-HC-2 V2 KUKA Deutschland GmbH KP1-H-2; KP1-HC-2 © Copyright 2022 KUKA Deutschland GmbH Zugspitzstraße 140 D-86165 Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Deutschland GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. KIM-PS5-DOC Translation of the original documentation Publication: Pub MA KP1-H-HC-2 (PDF) en PB18009 Book structure: MA KP1-H-HC-2 V2.1 BS15769 Version: 2/289 | www.kuka.com MA KP1-H-HC-2 V2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 Contents 1 Introduction.............................................................................................. 9 1.1 1.2 1.3 1.4 Target group.......................................................................................................... Positioning system documentation........................................................................ Representation of warnings and notes................................................................. Terms used............................................................................................................ 9 9 9 10 2 Product description................................................................................. 13 2.1 2.2 2.3 2.4 Overview of the positioner.................................................................................... Description of the positioner................................................................................. Control and integration.......................................................................................... Intended use and misuse...................................................................................... 13 13 15 16 3 Safety......................................................................................................... 17 3.1 3.1.1 3.1.2 3.1.3 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 General.................................................................................................................. Disclaimer.............................................................................................................. EC declaration of conformity and declaration of incorporation............................ Terms in the “Safety” chapter............................................................................... Personnel............................................................................................................... Workspace, safety zone and danger zone........................................................... Overview of protective equipment........................................................................ Mechanical end stops........................................................................................... Mechanical axis limitation (optional)..................................................................... Options for moving the manipulator without drive energy................................... Labeling on the industrial robot............................................................................ Safety measures.................................................................................................... General safety measures...................................................................................... Transportation........................................................................................................ Start-up and recommissioning.............................................................................. Manual mode......................................................................................................... Automatic mode..................................................................................................... Maintenance and repair........................................................................................ Decommissioning, storage and disposal.............................................................. 17 17 18 18 20 21 21 22 22 22 23 23 23 25 26 27 28 29 31 4 Technical data.......................................................................................... 33 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.4 4.4.1 Technical data, overview....................................................................................... Technical data, KP1-H500 R800-2....................................................................... Basic data, KP1-H500 R800-2.............................................................................. Axis data, KP1-H500 R800-2................................................................................ Payloads, KP1-H500 R800-2................................................................................ Foundation loads, KP1-H500 R800-2................................................................... Technical data, KP1-H500 R1000-2..................................................................... Basic data, KP1-H500 R1000-2............................................................................ Axis data, KP1-H500 R1000-2.............................................................................. Payloads, KP1-H500 R1000-2.............................................................................. Foundation loads, KP1-H500 R1000-2................................................................. Technical data, KP1-H500 R1200-2..................................................................... Basic data, KP1-H500 R1200-2............................................................................ 33 36 36 38 40 41 42 42 44 46 47 48 48 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 3/289 KP1-H-2; KP1-HC-2 4.4.2 4.4.3 4.4.4 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.10 4.10.1 4.10.2 4.10.3 4.10.4 4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.12 4.12.1 4.12.2 4.12.3 4.12.4 4.13 4.13.1 4.13.2 4.13.3 4.13.4 4.14 Axis data, KP1-H500 R1200-2.............................................................................. Payloads, KP1-H500 R1200-2.............................................................................. Foundation loads, KP1-H500 R1200-2................................................................. Technical data, KP1-H750 R800-2....................................................................... Basic data, KP1-H750 R800-2.............................................................................. Axis data, KP1-H750 R800-2................................................................................ Payloads, KP1-H750 R800-2................................................................................ Foundation loads, KP1-H750 R800-2................................................................... Technical data, KP1-H750 R1000-2..................................................................... Basic data, KP1-H750 R1000-2............................................................................ Axis data, KP1-H750 R1000-2.............................................................................. Payloads, KP1-H750 R1000-2.............................................................................. Foundation loads, KP1-H750 R1000-2................................................................. Technical data, KP1-H750 R1200-2..................................................................... Basic data, KP1-H750 R1200-2............................................................................ Axis data, KP1-H750 R1200-2.............................................................................. Payloads, KP1-H750 R1200-2.............................................................................. Foundation loads, KP1-H750 R1200-2................................................................. Technical data, KP1-H1000 R800-2..................................................................... Basic data, KP1-H1000 R800-2............................................................................ Axis data, KP1-H1000 R800-2.............................................................................. Payloads, KP1-H1000 R800-2.............................................................................. Foundation loads, KP1-H1000 R800-2................................................................. Technical data, KP1-H1000 R1000-2................................................................... Basic data, KP1-H1000 R1000-2.......................................................................... Axis data, KP1-H1000 R1000-2............................................................................ Payloads, KP1-H1000 R1000-2............................................................................ Foundation loads, KP1-H1000 R1000-2............................................................... Technical data, KP1-H1000 R1200-2................................................................... Basic data, KP1-H1000 R1200-2.......................................................................... Axis data, KP1-H1000 R1200-2............................................................................ Payloads, KP1-H1000 R1200-2............................................................................ Foundation loads, KP1-H1000 R1200-2............................................................... Technical data, KP1-H1500 R800-2..................................................................... Basic data, KP1-H1500 R800-2............................................................................ Axis data, KP1-H1500 R800-2.............................................................................. Payloads, KP1-H1500 R800-2.............................................................................. Foundation loads, KP1-H1500 R800-2................................................................. Technical data, KP1-H1500 R1000-2................................................................... Basic data, KP1-H1500 R1000-2.......................................................................... Axis data, KP1-H1500 R1000-2............................................................................ Payloads, KP1-H1500 R1000-2............................................................................ Foundation loads, KP1-H1500 R1000-2............................................................... Technical data, KP1-H1500 R1200-2................................................................... Basic data, KP1-H1500 R1200-2.......................................................................... Axis data, KP1-H1500 R1200-2............................................................................ Payloads, KP1-H1500 R1200-2............................................................................ Foundation loads, KP1-H1500 R1200-2............................................................... Technical data, KP1-HC500 R800-2..................................................................... 4/289 | www.kuka.com 50 52 53 54 54 56 58 59 60 60 62 64 65 66 66 68 70 71 72 72 74 76 77 78 78 80 82 83 84 84 86 88 89 90 90 92 94 95 96 96 98 100 101 102 102 104 106 107 108 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 4.14.1 4.14.2 4.14.3 4.14.4 4.15 4.15.1 4.15.2 4.15.3 4.15.4 4.16 4.16.1 4.16.2 4.16.3 4.16.4 4.17 4.17.1 4.17.2 4.17.3 4.17.4 4.18 4.18.1 4.18.2 4.18.3 4.18.4 4.19 4.19.1 4.19.2 4.19.3 4.19.4 4.20 4.20.1 4.20.2 4.20.3 4.20.4 4.21 4.21.1 4.21.2 4.21.3 4.21.4 4.22 4.22.1 4.22.2 4.22.3 4.22.4 4.23 4.23.1 4.23.2 4.23.3 4.23.4 Basic data, KP1-HC500 R800-2........................................................................... Axis data, KP1-HC500 R800-2............................................................................. Payloads, KP1-HC500 R800-2............................................................................. Foundation loads, KP1-HC500 R800-2................................................................ Technical data, KP1-HC500 R1000-2................................................................... Basic data, KP1-HC500 R1000-2......................................................................... Axis data, KP1-HC500 R1000-2........................................................................... Payloads, KP1-HC500 R1000-2........................................................................... Foundation loads, KP1-HC500 R1000-2.............................................................. Technical data, KP1-HC500 R1200-2................................................................... Basic data, KP1-HC500 R1200-2......................................................................... Axis data, KP1-HC500 R1200-2........................................................................... Payloads, KP1-HC500 R1200-2........................................................................... Foundation loads, KP1-HC500 R1200-2.............................................................. Technical data, KP1-HC750 R800-2..................................................................... Basic data, KP1-HC750 R800-2........................................................................... Axis data, KP1-HC750 R800-2............................................................................. Payloads, KP1-HC750 R800-2............................................................................. Foundation loads, KP1-HC750 R800-2................................................................ Technical data, KP1-HC750 R1000-2................................................................... Basic data, KP1-HC750 R1000-2......................................................................... Axis data, KP1-HC750 R1000-2........................................................................... Payloads, KP1-HC750 R1000-2........................................................................... Foundation loads, KP1-HC750 R1000-2.............................................................. Technical data, KP1-HC750 R1200-2................................................................... Basic data, KP1-HC750 R1200-2......................................................................... Axis data, KP1-HC750 R1200-2........................................................................... Payloads, KP1-HC750 R1200-2........................................................................... Foundation loads, KP1-HC750 R1200-2.............................................................. Technical data, KP1-HC1000 R800-2................................................................... Basic data, KP1-HC1000 R800-2......................................................................... Axis data, KP1-HC1000 R800-2........................................................................... Payloads, KP1-HC1000 R800-2........................................................................... Foundation loads, KP1-HC1000 R800-2.............................................................. Technical data, KP1-HC1000 R1000-2................................................................. Basic data, KP1-HC1000 R1000-2....................................................................... Axis data, KP1-HC1000 R1000-2......................................................................... Payloads, KP1-HC1000 R1000-2......................................................................... Foundation loads, KP1-HC1000 R1000-2............................................................ Technical data, KP1-HC1000 R1200-2................................................................. Basic data, KP1-HC1000 R1200-2....................................................................... Axis data, KP1-HC1000 R1200-2......................................................................... Payloads, KP1-HC1000 R1200-2......................................................................... Foundation loads, KP1-HC1000 R1200-2............................................................ Technical data, KP1-HC1500 R800-2................................................................... Basic data, KP1-HC1500 R800-2......................................................................... Axis data, KP1-HC1500 R800-2........................................................................... Payloads, KP1-HC1500 R800-2........................................................................... Foundation loads, KP1-HC1500 R800-2.............................................................. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 108 110 112 113 114 114 116 118 119 120 120 122 124 125 126 126 128 130 131 132 132 134 136 137 138 138 140 142 143 144 144 146 148 149 150 150 152 154 155 156 156 158 160 161 162 162 164 166 167 www.kuka.com | 5/289 KP1-H-2; KP1-HC-2 4.24 4.24.1 4.24.2 4.24.3 4.24.4 4.25 4.25.1 4.25.2 4.25.3 4.25.4 4.26 4.27 4.28 Technical data, KP1-HC1500 R1000-2................................................................. Basic data, KP1-HC1500 R1000-2....................................................................... Axis data, KP1-HC1500 R1000-2......................................................................... Payloads, KP1-HC1500 R1000-2......................................................................... Foundation loads, KP1-HC1500 R1000-2............................................................ Technical data, KP1-HC1500 R1200-2................................................................. Basic data, KP1-HC1500 R1200-2....................................................................... Axis data, KP1-HC1500 R1200-2......................................................................... Payloads, KP1-HC1500 R1200-2......................................................................... Foundation loads, KP1-HC1500 R1200-2............................................................ Plates and labels................................................................................................... REACH duty to communicate information acc. to Art. 33................................... Stopping distances................................................................................................ 168 168 170 172 173 174 174 176 178 179 180 182 182 5 Planning.................................................................................................... 183 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Information for planning........................................................................................ Mounting base....................................................................................................... Drive unit............................................................................................................... Counterbearing unit............................................................................................... Dimensions of face plates..................................................................................... Counterbearing variants........................................................................................ Connecting cables and interfaces......................................................................... 183 183 186 188 190 193 194 6 Transportation.......................................................................................... 197 6.1 6.1.1 6.1.2 Overview of transportation.................................................................................... Transporting the drive unit.................................................................................... Transportation of counterbearing unit................................................................... 197 197 199 7 Start-up and recommissioning............................................................... 203 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.4 Starting up the positioner KP1-H-2 (mounting base)........................................... Installing the mounting base................................................................................. Installing the positioner......................................................................................... Connecting the connecting cables........................................................................ Machine data......................................................................................................... Mastering the positioner........................................................................................ Concluding work.................................................................................................... Starting up the positioner KP1-HC-2 (mounting base)........................................ Installing the mounting base................................................................................. Installing the positioner......................................................................................... Connecting the connecting cables........................................................................ Machine data......................................................................................................... Mastering the positioner........................................................................................ Concluding work.................................................................................................... Description of the connecting cables, KR C4...................................................... Description of the Motor cable.............................................................................. Description of the Control cable, single axis........................................................ Description of the Resolver cable......................................................................... Description of the Resolver cable extension........................................................ Description of the ground conductor.................................................................... Description of the connecting cables, KR C5...................................................... 6/289 | www.kuka.com 203 206 207 208 209 210 212 212 215 216 218 219 220 221 222 223 224 225 226 228 228 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 7.4.1 7.4.2 7.4.3 Description of the Motor cable.............................................................................. Description of the Data cable............................................................................... Description of the ground conductor.................................................................... 8 Maintenance.............................................................................................. 233 8.1 8.1.1 8.2 8.2.1 8.2.2 Maintenance overview........................................................................................... Maintenance table................................................................................................. Cleaning the positioner......................................................................................... Cleaning................................................................................................................. Concluding work.................................................................................................... 233 234 235 236 236 9 Repair........................................................................................................ 237 9.1 9.1.1 9.1.2 9.1.3 9.2 9.2.1 9.2.2 9.2.3 Exchanging motor A1; rated payload 500 kg and 750 kg................................... Removing motor A1.............................................................................................. Installing motor A1................................................................................................ Concluding work.................................................................................................... Exchanging motor A1; rated payload 1000 kg and 1500 kg............................... Removing motor A1.............................................................................................. Installing motor A1................................................................................................ Concluding work.................................................................................................... 237 239 239 240 240 242 243 244 10 Decommissioning, storage and disposal............................................. 245 10.1 10.1.1 10.1.2 10.1.3 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.3 10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.4 10.4.1 10.4.2 10.4.3 10.4.4 10.4.5 10.4.6 10.5 Decommissioning, KP1-H-2.................................................................................. Releasing and disconnecting the connecting cables........................................... Removing the drive unit........................................................................................ Concluding work.................................................................................................... Decommissioning, KP1-HC-2................................................................................ Releasing and disconnecting the connecting cables........................................... Removing the drive unit........................................................................................ Removing the counterbearing unit........................................................................ Concluding work.................................................................................................... Storage, KP1-H-2.................................................................................................. Releasing and disconnecting the connecting cables........................................... Removing the drive unit........................................................................................ Cleaning................................................................................................................. Preparing for storage............................................................................................ Concluding work.................................................................................................... Storage, KP1-HC-2................................................................................................ Releasing and disconnecting the connecting cables........................................... Removing the drive unit........................................................................................ Removing the counterbearing unit........................................................................ Cleaning................................................................................................................. Preparing for storage............................................................................................ Concluding work.................................................................................................... Disposal................................................................................................................. 245 246 246 247 247 248 249 250 251 251 253 253 254 255 255 255 256 257 258 259 259 260 260 11 Options...................................................................................................... 261 11.1 11.1.1 11.1.1.1 Current collector (optional).................................................................................... Putting current collector into operation, drive unit............................................... Removing the cover on the drive side................................................................. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 230 231 232 261 264 265 www.kuka.com | 7/289 KP1-H-2; KP1-HC-2 11.1.1.2 11.1.1.3 11.1.1.4 11.1.2 11.1.2.1 11.1.2.2 11.1.2.3 11.1.2.4 11.1.3 11.1.3.1 11.1.3.2 11.1.3.3 11.1.3.4 11.1.3.5 11.1.4 11.1.4.1 11.1.4.2 11.1.4.3 11.1.4.4 11.1.4.5 Installing the current collector............................................................................... Installing the cover on the drive side................................................................... Concluding work.................................................................................................... Putting current collector into operation, counterbearing unit............................... Removing the cover from the counterbearing...................................................... Installing the current collector............................................................................... Installing the cover on the counterbearing........................................................... Concluding work.................................................................................................... Exchanging the current collector, drive unit......................................................... Removing the cover on the drive side................................................................. Removing the current collector............................................................................. Installing the current collector............................................................................... Installing the cover on the drive side................................................................... Concluding work.................................................................................................... Exchanging the current collector, counterbearing unit......................................... Removing the cover from the counterbearing...................................................... Removing the current collector............................................................................. Installing the current collector............................................................................... Installing the cover on the counterbearing........................................................... Concluding work.................................................................................................... 265 266 267 267 268 269 270 271 271 272 273 273 274 275 275 276 277 278 279 280 12 Appendix................................................................................................... 281 12.1 12.2 12.3 12.4 Tightening torques................................................................................................. Auxiliary and operating materials used................................................................ Weld seams - Quality requirements..................................................................... Applied standards and regulations....................................................................... 281 282 282 283 13 KUKA Service........................................................................................... 285 13.1 13.2 Requesting support............................................................................................... KUKA Customer Support...................................................................................... 285 285 Index 287 8/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 1 Introduction 1.1 Target group Introduction KP1-H-2; KP1-HC-2 This documentation is aimed at users with the following knowledge and skills: • • • • • Advanced knowledge of mechanical engineering Advanced knowledge of electrical and electronic systems Advanced knowledge of programming external axes Advanced knowledge of machine data Knowledge of the robot controller system For optimal use of KUKA products, we recommend the training courses offered by KUKA College. Information about the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries. 1.2 Positioning system documentation The positioner documentation consists of the following parts: • • • • • • Documentation for the positioner Documentation for the robot controller Documentation for the smartPAD-2 (if used) Operating and programming instructions for the System Software Instructions for options and accessories Spare parts overview in KUKA Xpert Each set of instructions is a separate document. 1.3 Representation of warnings and notes Safety These warnings are provided for safety purposes and must be observed. DANGER These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions are taken. WARNING These warnings mean that death or severe injuries may occur, if no precautions are taken. CAUTION These warnings mean that minor injuries may occur, if no precautions are taken. NOTICE These warnings mean that damage to property may occur, if no precautions are taken. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 9/289 Introduction KP1-H-2; KP1-HC-2 These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: SAFETY INSTRUCTION The following procedure must be followed exactly! Procedures marked with this warning must be followed exactly. Notices These notices serve to make your work easier or contain references to further information. Tip to make your work easier or reference to further information. 1.4 Terms used The overview may contain terms symbols that are not relevant for this document. Axis range Range within which the axis may move The axis range must be defined for each axis. Stopping distance Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. Drive unit A combination of motor and gear unit. Workspace Area within which the robot may move. The workspace is derived from the individual axis ranges. EMD Electronic Mastering Device The EMD is used for mastering the positioner with the KR C4. EMT Electronic measuring tool The EMT is used for mastering the positioner with the KR C2. Danger zone The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). KCP KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. KP KUKA positioner KR C KUKA Robot Control Robot controller KUKA smartPAD see “smartPAD” KUKA smartPAD-2 see “smartPAD” 10/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Manipulator The robot arm and the associated electrical installations RDC Resolver Digital Converter The resolver digital converter is used to acquire motor data (e.g. position data, motor temperatures). RDC Resolver Digital Converter Safety zone The safety zone is situated outside the danger zone. smartPAD Teach pendant for the robot controller The smartPAD has all the operator control and display functions required for operation and programming. The following models exist: • KUKA smartPAD • KUKA smartPAD-2 • KUKA smartPAD pro For robot controllers of the KR C5 series with KUKA System Software or VW System Software, only the model KUKA smartPAD-2 is used. For robot controllers of the KR C5 series with KUKA iiQKA.OS, only the model KUKA smartPAD pro is used. For other robot controllers, the designation “KUKA smartPAD” or “smartPAD” always refers to all models possible for the respective controller unless an explicit distinction is made. Stop category 0 The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called “STOP 0” in this document. Stop category 1 The manipulator and any external axes (optional) perform pathmaintaining braking. The drives are only disconnected once the machine has come to a standstill. Note: This stop category is called “STOP 1” in this document. Stop category 2 The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a path-maintaining braking ramp. Note: This stop category is called “STOP 2” in this document. T1 Test mode, Manual Reduced Velocity (<= 250 mm/s) T2 Test mode, Manual High Velocity (> 250 mm/s permissible) External axis Motion axis which is not part of the manipulator but is controlled by the robot controller, e.g. KUKA linear unit, turn-tilt table, positioner. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 11/289 Introduction KP1-H-2; KP1-HC-2 Introduction KP1-H-2; KP1-HC-2 12/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 2 Product description 2.1 Overview of the positioner The product families KP1-H-2 and KP1-HC-2 comprise the following positioner types: Type Payload Figure KP1-H-2, drive unit without counterbearing • KP1-H500 R800-2 • KP1-H500 R1000-2 • KP1-H500 R1200-2 500 kg • KP1-H750 R800-2 • KP1-H750 R1000-2 • KP1-H750 R1200-2 750 kg • KP1-H1000 R800-2 • KP1-H1000 R1000-2 • KP1-H1000 R1200-2 1000 kg • KP1-H1500 R800-2 • KP1-H1500 R1000-2 • KP1-H1500 R1200-2 1500 kg KP1-HC-2, drive unit with counterbearing • KP1-HC500 R800-2 • KP1-HC500 R1000-2 • KP1-HC500 R1200-2 500 kg • KP1-HC750 R800-2 • KP1-HC750 R1000-2 • KP1-HC750 R1200-2 750 kg • KP1-HC1000 R800-2 • KP1-HC1000 R1000-2 • KP1-HC1000 R1200-2 1000 kg • KP1-HC1500 R800-2 • KP1-HC1500 R1000-2 • KP1-HC1500 R1200-2 1500 kg 2.2 Description of the positioner Overview The positioner has one axis, which is controlled via the robot controller. A customer-specific or project-specific fixture is mounted by means of a mechanical interface (e.g. locating holes and threaded holes). The system may optionally have an energy supply system integrated into it (e.g. for compressed air, electrical current). In this document, this axis is referred to as axis 1 (A1). In the actual application, A1 might already be assigned to a different system component. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 13/289 Product description KP1-H-2; KP1-HC-2 Product description KP1-H-2; KP1-HC-2 Fig. 2-1: Main assemblies, KP1-H-2 and KP1-HC-2 1 KP1-H-2 2 KP1-HC-2 3 Face plate, drive 4 Drive pedestal 5 Booster frame 6 Face plate, counterbearing 7 Counterbearing pedestal Drive pedestal The positioners of the product family KP1-H-2 consist of a drive pedestal that is bolted to the booster frame. The drive pedestal houses the face plate and the motor. The face plate is electrically insulated. The positioners of the product family KP1-HC-2 consist of a drive pedestal and a counterbearing pedestal. Counterbearing pedestal The positioners of the product family KP1-HC-2 also include a counterbearing pedestal that is bolted to the booster frame. The counterbearing pedestal houses the face plate and the counterbearing. The face plate is electrically insulated. Booster frame The booster frame is the base of the positioners and raises the installation position of the respective pedestal. It is bolted to the floor. Electrical installations The electrical installations include the motor and resolver cables for the motor. All connections are pluggable. Accessories Only accessories authorized by KUKA Deutschland for this positioner may be used. All items of equipment must possess the appropriate certification and EC declarations of conformity. 14/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options The positioner can be equipped and operated with various options, e.g. an energy supply system and support strips. The options are described in separate documentation. The following options are also available: • Weld current return cable 2.3 Control and integration Description The drive units of the positioner are operated as external axes of the robot controller. The following couplings are possible: • Asynchronous operation. There is no mathematical coupling with the robot. • Mathematical coupling of one or more drive units into the robot kinematic system. Root point calibration is required for the mathematical coupling. Further information about calibration of an external kinematic system is contained in the Operating and Programming Instructions for System Integrators. An example of a mathematical coupling is depicted in the following diagram. Fig. 2-2: Robot with external axes and extended kinematic system With mathematical coupling, the robot constantly follows the movement of the coupled external axes. The mathematical coupling can simplify the programming for complex processes, e.g. arc welding. Using this method, a constant defined orientation can be maintained during a CP motion, for example. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 15/289 Product description KP1-H-2; KP1-HC-2 Product description KP1-H-2; KP1-HC-2 2.4 Intended use and misuse Intended use The positioner is intended to move and position loads and workpieces. Use is only permitted under the specified environmental conditions. Operation of the positioner in accordance with its intended use also requires compliance with the operating and assembly instructions for the individual components, with particular reference to the maintenance specifications. Misuse Any use or application deviating from the intended use is deemed to be misuse and is not allowed. It will result in the loss of warranty and liability claims. KUKA is not liable for any damage resulting from such misuse. This includes e.g.: • • • • • • • • Use as a climbing aid Operation outside the specified operating parameters Operation without the required safety equipment Transportation of persons and animals Outdoor operation. Use in a potentially explosive area Use in radioactive environments Operation in underground mining NOTICE Deviations from the operating conditions specified in the technical data or the use of special functions or applications can lead to premature wear. KUKA Deutschland GmbH must be consulted. The positioner is an integral part of an overall system and may only be operated in a CE-compliant system. 16/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 3 Safety 3.1 General Safety KP1-H-2; KP1-HC-2 • This “Safety” chapter refers to a mechanical component of an industrial robot. • If the mechanical component is used together with a KUKA robot controller, the “Safety” chapter of the operating instructions or assembly instructions of the robot controller must be used! This contains all the information provided in this “Safety” chapter. It also contains additional safety information relating to the robot controller which must be observed. • Where this “Safety” chapter uses the term “industrial robot”, this also refers to the individual mechanical component if applicable. 3.1.1 Disclaimer The device described in this document is either an industrial robot or a component thereof. 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, accessories The industrial robot is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life and limb or cause damage to the industrial robot and to other material property. The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the industrial robot is subject to compliance with this document and with the declaration of incorporation supplied together with the industrial robot. Any functional disorders, especially those affecting safety, must be rectified immediately. Safety information Information about safety may not be construed against the manufacturer. Even if all safety instructions are followed, this is not a guarantee that the industrial robot will not cause personal injuries or material damage. No modifications may be carried out to the industrial robot without the authorization of the manufacturer. Unauthorized modifications will result in the loss of warranty and liability claims. Additional components (tools, software, etc.), not supplied by the manufacturer, may be integrated into the industrial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property. In addition to the Safety chapter, this document contains further safety instructions. These must also be observed. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 17/289 Safety KP1-H-2; KP1-HC-2 3.1.2 EC declaration of conformity and declaration of incorporation The industrial robot constitutes partly completed machinery as defined by the EC Machinery Directive. The industrial robot may only be put into operation if the following preconditions are met: • The industrial robot is integrated into a complete system. or: The industrial robot, together with other machinery, constitutes a complete system. or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added to the industrial robot. • The complete system complies with the EC Machinery Directive. This has been confirmed by means of a conformity assessment procedure. EC declaration of conformity The system integrator must issue an EC declaration of conformity for the complete system in accordance with the Machinery Directive. The EC declaration of conformity forms the basis for the CE mark for the system. The industrial robot must always be operated in accordance with the applicable national laws, regulations and standards. The robot controller has a CE mark in accordance with the EMC Directive and the Low Voltage Directive. Declaration of incorporation The partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery is not allowed until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. 3.1.3 Terms in the “Safety” chapter Term Description Axis range Range within which the axis may move The axis range must be defined for each axis. Stopping distance Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. Workspace Area within which the robot may move. The workspace is derived from the individual axis ranges. User The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. 18/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Service life The service life of a safety-relevant component begins at the time of delivery of the component to the customer. The service life is not affected by whether the component is used or not, as safety-relevant components are also subject to aging during storage. Danger zone The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). KCP KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. KUKA smartPAD see “smartPAD” KUKA smartPAD-2 see “smartPAD” Manipulator The robot arm and the associated electrical installations Safety zone The safety zone is situated outside the danger zone. Safety options Generic term for options which make it possible to configure additional safe monitoring functions in addition to the standard safety functions. Example: SafeOperation smartPAD Teach pendant for the robot controller The smartPAD has all the operator control and display functions required for operation and programming. The following models exist: • KUKA smartPAD • KUKA smartPAD-2 • KUKA smartPAD pro For robot controllers of the KR C5 series with KUKA System Software or VW System Software, only the model KUKA smartPAD-2 is used. For robot controllers of the KR C5 series with KUKA iiQKA.OS, only the model KUKA smartPAD pro is used. For other robot controllers, the designation “KUKA smartPAD” or “smartPAD” always refers to all models possible for the respective controller unless an explicit distinction is made. Stop category 0 The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called “STOP 0” in this document. Stop category 1 The manipulator and any external axes (optional) perform pathmaintaining braking. The drives are only disconnected once the machine has come to a standstill. Note: This stop category is called “STOP 1” in this document. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 19/289 Safety KP1-H-2; KP1-HC-2 Safety KP1-H-2; KP1-HC-2 Stop category 1 – Drive Ramp Stop The manipulator and any external axes (optional) perform path-oriented braking. The drives are only disconnected once the machine has come to a standstill. Note: This stop category is called “STOP 1 - DRS” in this document. Stop category 2 The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a path-maintaining braking ramp. Note: This stop category is called “STOP 2” in this document. System integrator (plant integrator) The system integrator is responsible for safely integrating the industrial robot into a complete system and commissioning it. T1 Test mode, Manual Reduced Velocity (<= 250 mm/s) T2 Test mode, Manual High Velocity (> 250 mm/s permissible) External axis Motion axis which is not part of the manipulator but is controlled by the robot controller, e.g. KUKA linear unit, turn-tilt table, positioner. 3.2 Personnel The following persons or groups of persons are defined for the industrial robot: • User • Personnel Qualification of personnel Work on the system must only be performed by personnel that is able to assess the tasks to be carried out and detect potential hazards. Death, severe injuries or damage to property may otherwise result. The following qualifications are required: • Adequate specialist training, knowledge and experience • Knowledge of the relevant operating or assembly instructions, knowledge of the relevant standards • All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety chapter. User The user must observe the labor laws and regulations. This includes e.g.: • The user must • The user must • The user must tive equipment comply with his monitoring obligations. carry out briefing at defined intervals. comply with the regulations relating to personal protec(PPE). Personnel Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. 20/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 Safety Personnel includes: • System integrator • Operators, subdivided into: ‒ Start-up, maintenance and service personnel ‒ Operating personnel ‒ Cleaning personnel System integrator The industrial robot is safely integrated into a complete system by the system integrator. The system integrator is responsible for the following tasks: • • • • • • • Installing the industrial robot Connecting the industrial robot Performing the risk assessment Implementing the required safety functions and safeguards Issuing the EC declaration of conformity Affixing the CE mark Creating the operating instructions for the system Operators The operator must meet the following preconditions: • The operator must be trained for the work to be carried out. • Work on the system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. 3.3 Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). The danger zone must be protected by means of physical safeguards to prevent danger to persons or the risk of material damage. The safeguards (e.g. safety gate) must be located outside the danger zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. There must be no shearing or crushing hazards at the loading and transfer areas. If there are no physical safeguards present, the requirements for collaborative operation in accordance with EN ISO 10218 must be met. 3.4 Overview of protective equipment The protective equipment of the mechanical component may include: • • • • Mechanical end stops Mechanical axis limitation (optional) Release device (optional) Brake release device (optional) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 21/289 Safety KP1-H-2; KP1-HC-2 • Labeling of danger areas Not all equipment is relevant for every mechanical component. 3.4.1 Mechanical end stops Depending on the robot variant, the axis ranges of the main and wrist axes of the manipulator are partially limited by mechanical end stops. Additional mechanical end stops can be installed on the external axes. WARNING Danger to life and limb following collision with obstacle If the manipulator or an external axis hits an obstruction or a mechanical end stop or mechanical axis limitation, the manipulator can no longer be operated safely. Death, injuries or damage to property may result. • Put manipulator out of operation. • KUKA must be consulted before it is put back into operation. 3.4.2 Mechanical axis limitation (optional) Some manipulators can be fitted with adjustable mechanical axis limitation systems in axes A1 to A3. The axis limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system. In the case of manipulators that are not designed to be fitted with mechanical axis limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechanical axis limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or mechanical limitations on the system side. There must be no shearing or crushing hazards at the loading and transfer areas. This option is not available for all robot models. Information on specific robot models can be obtained from the manufacturer. 3.4.3 Options for moving the manipulator without drive energy Qualification of personnel with regard to behavior in emergency situations In emergencies or other exceptional situations, it may be necessary to move the manipulator without drive energy. • Personnel must be trained in how to move the manipulator without drive energy. Description The following options may be available for moving the manipulator without drive energy after an accident or malfunction: • Release device (optional) The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive motors. 22/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 • Brake release device (option) The brake release device is designed for robot variants whose motors are not freely accessible. • Moving the wrist axes directly by hand There is no release device available for the wrist axes of variants in the low payload category. This is not necessary because the wrist axes can be moved directly by hand. Information about the options available for the various robot models and about how to use them can be found in the assembly and operating instructions for the robot or can be requested from the manufacturer. NOTICE Damage to property due to moving the manipulator without drive energy Moving the manipulator without drive energy can damage the motor brakes of the axes concerned. • Only move the manipulator without drive energy in emergencies, e.g. for rescuing persons. • Perform brake test. • The motor must be replaced if the brake has been damaged. 3.4.4 Labeling on the industrial robot All plates, labels, symbols and marks constitute safety-relevant parts of the industrial robot. They must not be modified or removed. Labeling on the industrial robot consists of: • • • • • • Identification plates Warning signs Safety symbols Designation labels Cable markings Rating plates Further information is contained in the technical data of the operating instructions or assembly instructions of the components of the industrial robot. 3.5 Safety measures 3.5.1 General safety measures The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the industrial robot even after the robot controller has been switched off and locked out. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possi- MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 23/289 Safety KP1-H-2; KP1-HC-2 KP1-H-2; KP1-HC-2 Safety ble, the manipulator and external axes must be secured by appropriate means. DANGER Risk of fatal injury due to non-operational safety functions or external safeguards In the absence of operational safety functions or safeguards, the industrial robot can cause death, severe injuries or damage to property. • If safety functions or safeguards are dismantled or deactivated, do not operate the industrial robot. DANGER Danger to life and limb of persons under the robot arm Sagging or falling parts can cause death or serious injuries. This applies at all times, e.g. also for assembly tasks or with the controller switched off. • Never loiter under the robot arm. CAUTION Risk of burns from hot motors The motors reach temperatures during operation which can cause burns. • Avoid contact. • Take appropriate safety precautions, e.g. wear protective gloves. Implants WARNING Danger to life due to malfunction of implants caused by motors and brakes Electric motors and brakes generate electric and magnetic fields. The fields can cause malfunctions in active implants, e.g. pacemakers. • Affected persons must maintain a minimum distance of 300 mm from motors and brakes. This applies to both energized and deenergized motors and brakes. KCP/smartPAD The user must ensure that the industrial robot is only operated with the KCP/smartPAD by authorized persons. If more than one KCP/smartPAD is used in the overall system, it must be ensured that each device is unambiguously assigned to the corresponding industrial robot. They must not be interchanged. WARNING Danger to life due to disconnected smartPAD/KCP If a smartPAD/KCP is disconnected, its EMERGENCY STOP device is not operational. There is a risk of connected and disconnected smartPADs/KCPs being interchanged. Death, injuries or damage to property may result. • Remove the disconnected smartPAD/KCP from the system immediately. • Store the disconnected smartPAD/KCP out of sight and reach of personnel working on the industrial robot. 24/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 External keyboard, external mouse An external keyboard and/or external mouse may only be used if the following conditions are met: • Start-up or maintenance work is being carried out. • The drives are switched off. • There are no persons in the danger zone. The KCP/smartPAD must not be used as long as an external keyboard and/or external mouse are connected to the control cabinet. The external keyboard and/or external mouse must be removed from the control cabinet as soon as the start-up or maintenance work is completed or the KCP/smartPAD is connected. Modifications After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes e.g. modifications of the external axes or to the software and configuration settings. Faults In the case of faults on the industrial robot, the following safety measures must be implemented immediately: • Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. • Indicate the fault by means of a label with a corresponding warning (tagout). • Keep a record of the faults. Carry out a functional test after the fault has been rectified. 3.5.2 Transportation Manipulator The prescribed transport position of the manipulator must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot. Avoid vibrations and impacts during transportation in order to prevent damage to the manipulator. Robot controller The prescribed transport position of the robot controller must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot controller. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 25/289 Safety KP1-H-2; KP1-HC-2 Safety KP1-H-2; KP1-HC-2 External axis (optional) The prescribed transport position of the external axis (e.g. KUKA linear unit, turn-tilt table, positioner) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis. 3.5.3 Start-up and recommissioning Before starting up systems and devices for the first time, a check must be carried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested. Changing default passwords The KUKA System Software is supplied with default passwords for the user groups. If the passwords are not changed, this enables unauthorized persons to log on. • Before start-up, change the passwords for the user groups. • Only communicate the passwords to authorized personnel. WARNING Danger to life and limb due to incorrectly assigned cables The robot controller is preconfigured for the specific industrial robot. The manipulator and other components can receive incorrect data if they are connected to a different robot controller. Death, severe injuries or damage to property may result. • Only connect the manipulator to the corresponding robot controller. Do not impair safety functions Additional components (e.g. cables and hoses) not supplied by KUKA may be integrated into the industrial robot. If the safety functions are not taken into consideration, this may result in death, severe injuries or damage to property. • Additional components must not impair or disable safety functions. NOTICE Damage to property due to condensation If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form. This may result in damage to property. • Wait until the internal cabinet temperature has adapted to the ambient temperature in order to avoid condensation. Function test The 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 with the specifications in the documentation. 26/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 • There is no damage to the robot that could be attributed to external forces. Example: Dents or abrasion that could be caused by an impact or collision. WARNING Danger to life and limb resulting from external forces The external application of force, such as an impact or a collision, can cause non-visible damage. For example, it can lead to a gradual loss of drive power from the motor, resulting in unintended movements of the manipulator. Death, severe injuries or damage to property may result from nonvisible damage. ‒ Check the robot for damage that could have been caused by external forces, e.g. dents or abrasion of paintwork. Check the motor and counterbalancing system particularly carefully. (Motor inspection not relevant for robots with internal motors.) ‒ In the case of damage, the affected components must be exchanged. • There are no foreign bodies or defective 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 local supply voltage and mains type. • The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. • The connecting cables are correctly connected and the connectors are locked. 3.5.4 Manual mode General Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes: • • • • Jog mode Teaching Programming Program verification The following must be taken into consideration in manual mode: • New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). • The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence. • Workpieces, tooling and other objects must not become jammed as a result of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off. • All setup work must be carried out, where possible, from outside the safeguarded area. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 27/289 Safety KP1-H-2; KP1-HC-2 Safety KP1-H-2; KP1-HC-2 Setup work in T1 If it can be avoided, there must be no persons inside the safeguarded area. If it is necessary to carry out setup work from inside the safeguarded area, the following must be taken into consideration in the operating mode Manual Reduced Velocity (T1): • If it can be avoided, there must be no more than one person inside the safeguarded area. • If it is necessary for there to be several persons inside the safeguarded area, the following must be observed: ‒ Each person must have an enabling device. ‒ All persons must have an unimpeded view of the industrial robot. ‒ Eye-contact between all persons must be possible at all times. • The operator must be so positioned that he can see into the danger zone and get out of harm’s way. • Unexpected motions of the manipulator cannot be ruled out, e.g. in the event of a fault. For this reason, an appropriate clearance must be maintained between persons and the manipulator, including the tool. Guide value: 50 cm. The minimum clearance may vary depending on local circumstances, the motion program and other factors. The minimum clearance that is to apply for the specific application must be decided by the user on the basis of a risk assessment. Setup work in T2 If it is necessary to carry out setup work from inside the safeguarded area, the following must be taken into consideration in the operating mode Manual High Velocity (T2): • This mode may only be used if the application requires a test at a velocity higher than that possible in T1 mode. • Teaching and programming are not permissible in this operating mode. • Before commencing the test, the operator must ensure that the enabling devices are operational. • The operator must be positioned outside the danger zone. • There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this. 3.5.5 Automatic mode Automatic mode is only permissible in compliance with the following safety measures: • All safety equipment and safeguards are present and operational. • There are no persons in the system or the requirements for collaborative operation in accordance with EN ISO 10218 have been met. • The defined working procedures are adhered to. If the manipulator or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered. 28/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 3.5.6 Safety KP1-H-2; KP1-HC-2 Maintenance and repair After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on the industrial robot: • Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel. • Switch off the industrial robot and secure it (e.g. with a padlock) to prevent it from being switched on again. If it is necessary to carry out work with the robot controller switched on, the user must define additional safety measures to ensure the safe protection of personnel. • If it is necessary to carry out work with the robot controller switched on, this may only be done in operating mode T1. • Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work. • The EMERGENCY STOP devices must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. DANGER Danger to life and limb due to live parts The robot system must be disconnected from the mains power supply prior to work on live parts. It is not sufficient to trigger an EMERGENCY STOP or safety stop, because parts remain live. Death or severe injuries may result. • Before commencing work on live parts, turn off the main switch and secure it against being switched on again. If the controller variant in question does not have a main switch (e.g. KR C5 micro), turn off the device switch then disconnect the power cable and secure it so it cannot be reconnected. • Then check to ensure that the system is deenergized. • Inform the individuals involved that the robot controller is switched off. (e.g. by affixing a warning sign) Faulty components must be replaced using new components with the same article numbers or equivalent components approved by the manufacturer for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions. Robot controller Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller. The ESD regulations must be adhered to when working on components in the robot controller. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 29/289 KP1-H-2; KP1-HC-2 Safety Voltages in excess of 50 V (up to 780 V) can be present in various components for several minutes after the robot controller has been switched off! To prevent life-threatening injuries, no work may be carried out on the industrial robot in this time. On robot controllers with transformers, the transformers must be disconnected before working on components in the robot controller. Water and dust must be prevented from entering the robot controller. Counterbalancing system Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbalancing system. • Counterbalancing system classified below category I: Is subject to the Pressure Equipment Directive but exempt from application of the Pressure Equipment Directive according to Art. 4, para. 3 and therefore not CE marked. • Counterbalancing system classified as category I or higher: Is subject to the Pressure Equipment Directive and CE marked as a component (see rating plate of the counterbalancing system). The pressure equipment is placed on the market in conjunction with partly completed machinery. Conformity is expressed on the declaration of incorporation according to the Machinery Directive. The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment. • In Germany, the counterbalancing system is work equipment according to the German Ordinance on Industrial Safety and Health (BetrSichV). Inspection intervals in Germany in accordance with the Ordinance on Industrial Safety and Health, Sections 14 and 15. Inspection by the user before commissioning at the installation site. • Inspection intervals in all other countries must be researched and observed. As a rule, however, at least the maintenance intervals specified by KUKA must be observed. These must not be exceeded. The following safety measures must be carried out when working on the counterbalancing system: • The assemblies supported by the counterbalancing systems must be secured. • Work on the counterbalancing systems must only be carried out by qualified personnel. Hazardous substances The following safety measures must be carried out when handling hazardous substances: • Avoid prolonged and repeated intensive contact with the skin. • Avoid breathing in oil spray or vapors. • Clean skin and apply skin cream. Use current safety data sheets Knowledge of the safety data sheets of the substances and mixtures used is a prerequisite for the safe use of KUKA products. Death, injuries or damage to property may otherwise result. • Request up-to-date safety data sheets from the manufacturers of hazardous substances regularly. 30/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 3.5.7 Safety KP1-H-2; KP1-HC-2 Decommissioning, storage and disposal The industrial robot must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 31/289 Safety KP1-H-2; KP1-HC-2 32/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 4 Technical data 4.1 Technical data, overview Technical data KP1-H-2; KP1-HC-2 The technical data for the individual positioner types can be found in the following sections: Positioner KP1-H-2 Technical data KP1-H500 R800-2 • Technical data (>>> 4.2 "Technical data, KP1-H500 R800-2" Page 36) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H500 R1000-2 • Technical data (>>> 4.3 "Technical data, KP1-H500 R1000-2" Page 42) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H500 R1200-2 • Technical data (>>> 4.4 "Technical data, KP1-H500 R1200-2" Page 48) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H750 R800-2 • Technical data (>>> 4.5 "Technical data, KP1-H750 R800-2" Page 54) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H750 R1000-2 • Technical data (>>> 4.6 "Technical data, KP1-H750 R1000-2" Page 60) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H750 R1200-2 • Technical data (>>> 4.7 "Technical data, KP1-H750 R1200-2" Page 66) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 33/289 Technical data KP1-H-2; KP1-HC-2 Positioner KP1-H-2 Technical data KP1-H1000 R800-2 • Technical data (>>> 4.8 "Technical data, KP1-H1000 R800-2" Page 72) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H1000 R1000-2 • Technical data (>>> 4.9 "Technical data, KP1-H1000 R1000-2" Page 78) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H1000 R1200-2 • Technical data (>>> 4.10 "Technical data, KP1-H1000 R1200-2" Page 84) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H1500 R800-2 • Technical data (>>> 4.11 "Technical data, KP1-H1500 R800-2" Page 90) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H1500 R1000-2 • Technical data (>>> 4.12 "Technical data, KP1-H1500 R1000-2" Page 96) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-H1500 R1200-2 • Technical data (>>> 4.13 "Technical data, KP1-H1500 R1200-2" Page 102) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) 34/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Positioner KP1-HC-2 Technical data KP1-HC500 R800-2 • Technical data (>>> 4.14 "Technical data, KP1-HC500 R800-2" Page 108) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC500 R1000-2 • Technical data (>>> 4.15 "Technical data, KP1-HC500 R1000-2" Page 114) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times KP1-HC500 R1200-2 • Technical data (>>> 4.16 "Technical data, KP1-HC500 R1200-2" Page 120) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC750 R800-2 • Technical data (>>> 4.17 "Technical data, KP1-HC750 R800-2" Page 126) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC750 R1000-2 • Technical data (>>> 4.18 "Technical data, KP1-HC750 R1000-2" Page 132) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC750 R1200-2 • Technical data (>>> 4.19 "Technical data, KP1-HC750 R1200-2" Page 138) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC1000 R800-2 • Technical data (>>> 4.20 "Technical data, KP1-HC1000 R800-2" Page 144) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 35/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Positioner KP1-HC-2 Technical data KP1-HC1000 R1000-2 • Technical data (>>> 4.21 "Technical data, KP1-HC1000 R1000-2" Page 150) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC1000 R1200-2 • Technical data (>>> 4.22 "Technical data, KP1-HC1000 R1200-2" Page 156) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC1500 R800-2 • Technical data (>>> 4.23 "Technical data, KP1-HC1500 R800-2" Page 162) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC1500 R1000-2 • Technical data (>>> 4.24 "Technical data, KP1-HC1500 R1000-2" Page 168) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) KP1-HC1500 R1200-2 • Technical data (>>> 4.25 "Technical data, KP1-HC1500 R1200-2" Page 174) • Plates and labels (>>> 4.26 "Plates and labels" Page 180) • Stopping distances and times (>>> 4.28 "Stopping distances" Page 182) 4.2 Technical data, KP1-H500 R800-2 4.2.1 Basic data, KP1-H500 R800-2 Basic data KP1-H500 R800-2 36/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 149 kg Rated payload 500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H500 R800-2 Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 37/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.2.2 Axis data, KP1-H500 R800-2 Axis data 38/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Turning time 180°, axis 1 2.5 s Turning time 360°, axis 1 4.2 s Mastering position A1 45 ° Technical data KP1-H-2; KP1-HC-2 Mastering positions Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-1: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 39/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-2: Working envelope, side view, KP1-H500 R800-2 4.2.3 1 Height: 1040 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-H500 R800-2 Payloads Rated payload 500 kg Maximum load torque A1 736 Nm Mass moment of inertia A1 359 kgm² Nominal distance to load center of gravity 40/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-3: Load center of gravity 4.2.4 Foundation loads, KP1-H500 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 7810 N F(v max) 8289 N Horizontal force F(h) F(h normal) 274 N F(h max) 753 N Tilting moment M(k) M(k normal) 2218 Nm M(k max) 2414 Nm Torque about axis 1 M(r) M(r normal) 2047 Nm M(r max) 4342 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 41/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-4: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.3 Technical data, KP1-H500 R1000-2 4.3.1 Basic data, KP1-H500 R1000-2 Basic data KP1-H500 R1000-2 42/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 158 kg Rated payload 500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H500 R1000-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 43/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.3.2 Axis data, KP1-H500 R1000-2 Axis data 44/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.5 s Turning time 360°, axis 1 4.2 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-5: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 45/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-6: Working envelope, side view, KP1-H500 R1000-2 4.3.3 1 Height: 1240 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-H500 R1000-2 Payloads Rated payload 500 kg Maximum load torque A1 736 Nm Mass moment of inertia A1 359 kgm² Nominal distance to load center of gravity 46/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-7: Load center of gravity 4.3.4 Foundation loads, KP1-H500 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 7927 N F(v max) 8406 N Horizontal force F(h) F(h normal) 274 N F(h max) 753 N Tilting moment M(k) M(k normal) 2223 Nm M(k max) 2418 Nm Torque about axis 1 M(r) M(r normal) 2047 Nm M(r max) 4342 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 47/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-8: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.4 Technical data, KP1-H500 R1200-2 4.4.1 Basic data, KP1-H500 R1200-2 Basic data KP1-H500 R1200-2 48/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 168 kg Rated payload 500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H500 R1200-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 49/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.4.2 Axis data, KP1-H500 R1200-2 Axis data 50/289 | www.kuka.com Loading height 1240 mm Tool radius 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.5 s Turning time 360°, axis 1 4.2 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-9: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 51/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-10: Working envelope, side view, KP1-H500 R1200-2 4.4.3 1 Height: 1440 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-H500 R1200-2 Payloads Rated payload 500 kg Maximum load torque A1 736 Nm Mass moment of inertia A1 359 kgm² Nominal distance to load center of gravity 52/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-11: Load center of gravity 4.4.4 Foundation loads, KP1-H500 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 8041 N F(v max) 8520 N Horizontal force F(h) F(h normal) 274 N F(h max) 753 N Tilting moment M(k) M(k normal) 2227 Nm M(k max) 2423 Nm Torque about axis 1 M(r) M(r normal) 2047 Nm M(r max) 4342 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 53/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-12: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.5 Technical data, KP1-H750 R800-2 4.5.1 Basic data, KP1-H750 R800-2 Basic data KP1-H750 R800-2 54/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 149 kg Rated payload 750 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H750 R800-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 55/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.5.2 Axis data, KP1-H750 R800-2 Axis data 56/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-13: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 57/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-14: Working envelope, side view, KP1-H750 R800-2 4.5.3 1 Height: 1040 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-H750 R800-2 Payloads Rated payload 750 kg Maximum load torque A1 1104 Nm Mass moment of inertia A1 539 kgm² Nominal distance to load center of gravity 58/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-15: Load center of gravity 4.5.4 Foundation loads, KP1-H750 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 10212 N F(v max) 10695 N Horizontal force F(h) F(h normal) 223 N F(h max) 707 N Tilting moment M(k) M(k normal) 3093 Nm M(k max) 3290 Nm Torque about axis 1 M(r) M(r normal) 2173 Nm M(r max) 4490 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 59/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-16: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.6 Technical data, KP1-H750 R1000-2 4.6.1 Basic data, KP1-H750 R1000-2 Basic data KP1-H750 R1000-2 60/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 158 kg Rated payload 750 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H750 R1000-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 61/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.6.2 Axis data, KP1-H750 R1000-2 Axis data 62/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-17: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 63/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-18: Working envelope, side view, KP1-H750 R1000-2 4.6.3 1 Height: 1040 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-H750 R1000-2 Payloads Rated payload 750 kg Maximum load torque A1 1104 Nm Mass moment of inertia A1 539 kgm² Nominal distance to load center of gravity 64/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-19: Load center of gravity 4.6.4 Foundation loads, KP1-H750 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 10329 N F(v max) 10813 N Horizontal force F(h) F(h normal) 223 N F(h max) 707 N Tilting moment M(k) M(k normal) 3093 Nm M(k max) 3290 Nm Torque about axis 1 M(r) M(r normal) 2173 Nm M(r max) 4490 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 65/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-20: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.7 Technical data, KP1-H750 R1200-2 4.7.1 Basic data, KP1-H750 R1200-2 Basic data KP1-H750 R1200-2 66/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 168 kg Rated payload 750 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H750 R1200-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 67/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.7.2 Axis data, KP1-H750 R1200-2 Axis data 68/289 | www.kuka.com Loading height 1240 mm Tool radius 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-21: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 69/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-22: Working envelope, side view, KP1-H750 R1200-2 4.7.3 1 Height: 1440 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-H750 R1200-2 Payloads Rated payload 750 kg Maximum load torque A1 1104 Nm Mass moment of inertia A1 539 kgm² Nominal distance to load center of gravity 70/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-23: Load center of gravity 4.7.4 Foundation loads, KP1-H750 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 10443 N F(v max) 10927 N Horizontal force F(h) F(h normal) 223 N F(h max) 707 N Tilting moment M(k) M(k normal) 3093 Nm M(k max) 3290 Nm Torque about axis 1 M(r) M(r normal) 2173 Nm M(r max) 4490 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 71/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-24: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.8 Technical data, KP1-H1000 R800-2 4.8.1 Basic data, KP1-H1000 R800-2 Basic data KP1-H1000 R800-2 72/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 213 kg Rated payload 1000 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H1000 R800-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 73/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.8.2 Axis data, KP1-H1000 R800-2 Axis data 74/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.3 s Turning time 360°, axis 1 3.9 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-25: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 75/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-26: Working envelope, side view, KP1-H1000 R800-2 4.8.3 1 Height: 1090 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-H1000 R800-2 Payloads Rated payload 1000 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 719 kgm² Nominal distance to load center of gravity 76/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-27: Load center of gravity 4.8.4 Foundation loads, KP1-H1000 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 13581 N F(v max) 14009 N Horizontal force F(h) F(h normal) 514 N F(h max) 942 N Tilting moment M(k) M(k normal) 4212 Nm M(k max) 4387 Nm Torque about axis 1 M(r) M(r normal) 3934 Nm M(r max) 5987 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 77/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-28: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.9 Technical data, KP1-H1000 R1000-2 4.9.1 Basic data, KP1-H1000 R1000-2 Basic data KP1-H1000 R1000-2 78/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 222 kg Rated payload 1000 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H1000 R1000-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 79/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.9.2 Axis data, KP1-H1000 R1000-2 Axis data 80/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.3 s Turning time 360°, axis 1 3.9 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-29: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 81/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-30: Working envelope, side view, KP1-H1000 R1000-2 4.9.3 1 Height: 1290 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-H1000 R1000-2 Payloads Rated payload 1000 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 719 kgm² Nominal distance to load center of gravity 82/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-31: Load center of gravity 4.9.4 Foundation loads, KP1-H1000 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 13699 N F(v max) 14127 N Horizontal force F(h) F(h normal) 514 N F(h max) 942 N Tilting moment M(k) M(k normal) 4212 Nm M(k max) 4387 Nm Torque about axis 1 M(r) M(r normal) 3934 Nm M(r max) 5987 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 83/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-32: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.10 Technical data, KP1-H1000 R1200-2 4.10.1 Basic data, KP1-H1000 R1200-2 Basic data KP1-H1000 R1200-2 84/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 232 kg Rated payload 1000 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H1000 R1200-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 85/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.10.2 Axis data, KP1-H1000 R1200-2 Axis data 86/289 | www.kuka.com Loading height 1240 mm Tool radius 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.3 s Turning time 360°, axis 1 3.9 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-33: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 87/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-34: Working envelope, side view, KP1-H1000 R1200-2 4.10.3 1 Height: 1490 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-H1000 R1200-2 Payloads Rated payload 1000 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 719 kgm² Nominal distance to load center of gravity 88/289 | www.kuka.com Lx 200 mm Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-35: Load center of gravity 4.10.4 Foundation loads, KP1-H1000 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 13812 N F(v max) 14241 N Horizontal force F(h) F(h normal) 514 N F(h max) 942 N Tilting moment M(k) M(k normal) 4212 Nm M(k max) 4387 Nm Torque about axis 1 M(r) M(r normal) 3934 Nm M(r max) 5987 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 89/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-36: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.11 Technical data, KP1-H1500 R800-2 4.11.1 Basic data, KP1-H1500 R800-2 Basic data KP1-H1500 R800-2 90/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 213 kg Rated payload 1500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H1500 R800-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 91/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.11.2 Axis data, KP1-H1500 R800-2 Axis data 92/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-37: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 93/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-38: Working envelope, side view, KP1-H1500 R800-2 4.11.3 1 Height: 1090 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-H1500 R800-2 Payloads Rated payload 1500 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 1059 kgm² Nominal distance to load center of gravity 94/289 | www.kuka.com Lx 200 mm Lyz 100 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-39: Load center of gravity 4.11.4 Foundation loads, KP1-H1500 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 18325 N F(v max) 18914 N Horizontal force F(h) F(h normal) 353 N F(h max) 942 N Tilting moment M(k) M(k normal) 6148 Nm M(k max) 6388 Nm Torque about axis 1 M(r) M(r normal) 3967 Nm M(r max) 8127 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 95/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-40: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.12 Technical data, KP1-H1500 R1000-2 4.12.1 Basic data, KP1-H1500 R1000-2 Basic data KP1-H1500 R1000-2 96/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 222 kg Rated payload 1500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H1500 R1000-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 97/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.12.2 Axis data, KP1-H1500 R1000-2 Axis data 98/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-41: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 99/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-42: Working envelope, side view, KP1-H1500 R1000-2 4.12.3 1 Height: 1290 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-H1500 R1000-2 Payloads Rated payload 1500 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 1059 kgm² Nominal distance to load center of gravity 100/289 | www.kuka.com Lx 200 mm Lyz 100 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-43: Load center of gravity 4.12.4 Foundation loads, KP1-H1500 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 18443 N F(v max) 19032 N Horizontal force F(h) F(h normal) 353 N F(h max) 942 N Tilting moment M(k) M(k normal) 6148 Nm M(k max) 6388 Nm Torque about axis 1 M(r) M(r normal) 3967 Nm M(r max) 8127 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 101/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-44: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.13 Technical data, KP1-H1500 R1200-2 4.13.1 Basic data, KP1-H1500 R1200-2 Basic data KP1-H1500 R1200-2 102/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 232 kg Rated payload 1500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x 490 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-H1500 R1200-2 Hole pattern: mounting surface for kinematic system R412x640 Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 103/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.13.2 Axis data, KP1-H1500 R1200-2 Axis data 104/289 | www.kuka.com Loading height 1240 mm Tool radius max. 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-45: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 105/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-46: Working envelope, side view, KP1-H1500 R1200-2 4.13.3 1 Height: 1490 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-H1500 R1200-2 Payloads Rated payload 1500 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 1059 kgm² Nominal distance to load center of gravity 106/289 | www.kuka.com Lx 200 mm Lyz 100 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-47: Load center of gravity 4.13.4 Foundation loads, KP1-H1500 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 18557 N F(v max) 19146 N Horizontal force F(h) F(h normal) 353 N F(h max) 942 N Tilting moment M(k) M(k normal) 6148 Nm M(k max) 6388 Nm Torque about axis 1 M(r) M(r normal) 3967 Nm M(r max) 8127 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 107/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-48: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.14 Technical data, KP1-HC500 R800-2 4.14.1 Basic data, KP1-HC500 R800-2 Basic data KP1-HC500 R800-2 108/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 289 kg Rated payload 500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 Footprint 800 mm x (980 mm + distance between face plates) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 KP1-HC500 R800-2 Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 109/289 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.14.2 Axis data, KP1-HC500 R800-2 Axis data 110/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.5 s Turning time 360°, axis 1 4.2 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-49: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 111/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-50: Working envelope, side view, KP1-HC500 R800-2 4.14.3 1 Height: 1040 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-HC500 R800-2 Payloads Rated payload 500 kg Maximum load torque A1 736 Nm Mass moment of inertia A1 359 kgm² Nominal distance to load center of gravity 112/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-51: Load center of gravity 4.14.4 Foundation loads, KP1-HC500 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 10259 N F(v max) 10738 N Horizontal force F(h) F(h normal) 274 N F(h max) 753 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 2047 Nm M(r max) 4342 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 113/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-52: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.15 Technical data, KP1-HC500 R1000-2 4.15.1 Basic data, KP1-HC500 R1000-2 Basic data KP1-HC500 R1000-2 114/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 308 kg Rated payload 500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC500 R1000-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 115/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.15.2 Axis data, KP1-HC500 R1000-2 Axis data 116/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.5 s Turning time 360°, axis 1 4.2 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-53: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 117/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-54: Working envelope, side view, KP1-HC500 R1000-2 4.15.3 1 Height: 1240 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-HC500 R1000-2 Payloads Rated payload 500 kg Maximum load torque A1 736 Nm Mass moment of inertia A1 359 kgm² Nominal distance to load center of gravity 118/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-55: Load center of gravity 4.15.4 Foundation loads, KP1-HC500 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 10495 N F(v max) 10974 N Horizontal force F(h) F(h normal) 274 N F(h max) 753 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 2047 Nm M(r max) 4342 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 119/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-56: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.16 Technical data, KP1-HC500 R1200-2 4.16.1 Basic data, KP1-HC500 R1200-2 Basic data KP1-HC500 R1200-2 120/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 327 kg Rated payload 500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC500 R1200-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 121/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.16.2 Axis data, KP1-HC500 R1200-2 Axis data 122/289 | www.kuka.com Loading height 1240 mm Tool radius 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.5 s Turning time 360°, axis 1 4.2 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-57: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 123/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-58: Working envelope, side view, KP1-HC500 R1200-2 4.16.3 1 Height: 1440 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-HC500 R1200-2 Payloads Rated payload 500 kg Maximum load torque A1 736 Nm Mass moment of inertia A1 359 kgm² Nominal distance to load center of gravity 124/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-59: Load center of gravity 4.16.4 Foundation loads, KP1-HC500 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 10722 N F(v max) 11201 N Horizontal force F(h) F(h normal) 274 N F(h max) 753 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 2047 Nm M(r max) 4342 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 125/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-60: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.17 Technical data, KP1-HC750 R800-2 4.17.1 Basic data, KP1-HC750 R800-2 Basic data KP1-HC750 R800-2 126/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 289 kg Rated payload 750 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC750 R800-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 127/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.17.2 Axis data, KP1-HC750 R800-2 Axis data 128/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-61: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 129/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-62: Working envelope, side view, KP1-HC750 R800-2 4.17.3 1 Height: 1040 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-HC750 R800-2 Payloads Rated payload 750 kg Maximum load torque A1 1104 Nm Mass moment of inertia A1 539 kgm² Nominal distance to load center of gravity 130/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-63: Load center of gravity 4.17.4 Foundation loads, KP1-HC750 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 12661 N F(v max) 13145 N Horizontal force F(h) F(h normal) 223 N F(h max) 707 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 2173 Nm M(r max) 4490 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 131/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-64: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.18 Technical data, KP1-HC750 R1000-2 4.18.1 Basic data, KP1-HC750 R1000-2 Basic data KP1-HC750 R1000-2 132/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 308 kg Rated payload 750 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC750 R1000-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 133/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.18.2 Axis data, KP1-HC750 R1000-2 Axis data 134/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-65: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 135/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-66: Working envelope, side view, KP1-HC750 R1000-2 4.18.3 1 Height: 1240 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-HC750 R1000-2 Payloads Rated payload 750 kg Maximum load torque A1 1104 Nm Mass moment of inertia A1 539 kgm² Nominal distance to load center of gravity 136/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-67: Load center of gravity 4.18.4 Foundation loads, KP1-HC750 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 12897 N F(v max) 13380 N Horizontal force F(h) F(h normal) 223 N F(h max) 707 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 2173 Nm M(r max) 4490 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 137/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-68: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.19 Technical data, KP1-HC750 R1200-2 4.19.1 Basic data, KP1-HC750 R1200-2 Basic data KP1-HC750 R1200-2 138/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 327 kg Rated payload 750 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC750 R1200-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 139/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.19.2 Axis data, KP1-HC750 R1200-2 Axis data 140/289 | www.kuka.com Loading height 1240 mm Tool radius 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-69: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 141/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-70: Working envelope, side view, KP1-HC750 R1200-2 4.19.3 1 Height: 1440 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-HC750 R1200-2 Payloads Rated payload 750 kg Maximum load torque A1 1104 Nm Mass moment of inertia A1 539 kgm² Nominal distance to load center of gravity 142/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-71: Load center of gravity 4.19.4 Foundation loads, KP1-HC750 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 13124 N F(v max) 13608 N Horizontal force F(h) F(h normal) 223 N F(h max) 707 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 2173 Nm M(r max) 4490 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 143/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-72: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.20 Technical data, KP1-HC1000 R800-2 4.20.1 Basic data, KP1-HC1000 R800-2 Basic data KP1-HC1000 R800-2 144/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 352 kg Rated payload 1000 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC1000 R800-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 145/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.20.2 Axis data, KP1-HC1000 R800-2 Axis data 146/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.3 s Turning time 360°, axis 1 3.9 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-73: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 147/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-74: Working envelope, side view, KP1-HC1000 R800-2 4.20.3 1 Height: 1090 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-HC1000 R800-2 Payloads Rated payload 1000 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 719 kgm² Nominal distance to load center of gravity 148/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-75: Load center of gravity 4.20.4 Foundation loads, KP1-HC1000 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 16032 N F(v max) 16461 N Horizontal force F(h) F(h normal) 514 N F(h max) 942 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 3934 Nm M(r max) 5987 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 149/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-76: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.21 Technical data, KP1-HC1000 R1000-2 4.21.1 Basic data, KP1-HC1000 R1000-2 Basic data KP1-HC1000 R1000-2 150/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 372 kg Rated payload 1000 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC1000 R1000-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 151/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.21.2 Axis data, KP1-HC1000 R1000-2 Axis data 152/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.3 s Turning time 360°, axis 1 3.9 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-77: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 153/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-78: Working envelope, side view, KP1-HC1000 R1000-2 4.21.3 1 Height: 1290 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-HC1000 R1000-2 Payloads Rated payload 1000 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 719 kgm² Nominal distance to load center of gravity 154/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-79: Load center of gravity 4.21.4 Foundation loads, KP1-HC1000 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 16268 N F(v max) 16696 N Horizontal force F(h) F(h normal) 514 N F(h max) 942 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 3934 Nm M(r max) 5987 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 155/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-80: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.22 Technical data, KP1-HC1000 R1200-2 4.22.1 Basic data, KP1-HC1000 R1200-2 Basic data KP1-HC1000 R1200-2 156/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 391 kg Rated payload 1000 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC1000 R1200-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 157/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.22.2 Axis data, KP1-HC1000 R1200-2 Axis data 158/289 | www.kuka.com Loading height 1240 mm Tool radius 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.3 s Turning time 360°, axis 1 3.9 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-81: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 159/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-82: Working envelope, side view, KP1-HC1000 R1200-2 4.22.3 1 Height: 1490 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-HC1000 R1200-2 Payloads Rated payload 1000 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 719 kgm² Nominal distance to load center of gravity 160/289 | www.kuka.com Lx - Lyz 150 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-83: Load center of gravity 4.22.4 Foundation loads, KP1-HC1000 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 16496 N F(v max) 16924 N Horizontal force F(h) F(h normal) 514 N F(h max) 942 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 3934 Nm M(r max) 5987 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 161/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-84: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.23 Technical data, KP1-HC1500 R800-2 4.23.1 Basic data, KP1-HC1500 R800-2 Basic data KP1-HC1500 R800-2 162/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 352 kg Rated payload 1500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC1500 R800-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 163/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.23.2 Axis data, KP1-HC1500 R800-2 Axis data 164/289 | www.kuka.com Loading height 840 mm Tool radius 800 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-85: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 165/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-86: Working envelope, side view, KP1-HC1500 R800-2 4.23.3 1 Height: 1090 mm 2 Loading height: 840 mm 3 Tool radius: 800 mm Payloads, KP1-HC1500 R800-2 Payloads Rated payload 1500 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 1059 kgm² Nominal distance to load center of gravity 166/289 | www.kuka.com Lx - Lyz 100 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-87: Load center of gravity 4.23.4 Foundation loads, KP1-HC1500 R800-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 20777 N F(v max) 21366 N Horizontal force F(h) F(h normal) 353 N F(h max) 942 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 3967 Nm M(r max) 8127 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 167/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-88: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.24 Technical data, KP1-HC1500 R1000-2 4.24.1 Basic data, KP1-HC1500 R1000-2 Basic data KP1-HC1500 R1000-2 168/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 372 kg Rated payload 1500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC1500 R1000-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 169/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.24.2 Axis data, KP1-HC1500 R1000-2 Axis data 170/289 | www.kuka.com Loading height 1040 mm Tool radius 1000 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-89: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 171/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-90: Working envelope, side view, KP1-HC1500 R1000-2 4.24.3 1 Height: 1290 mm 2 Loading height: 1040 mm 3 Tool radius: 1000 mm Payloads, KP1-HC1500 R1000-2 Payloads Rated payload 1500 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 1059 kgm² Nominal distance to load center of gravity 172/289 | www.kuka.com Lx - Lyz 100 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-91: Load center of gravity 4.24.4 Foundation loads, KP1-HC1500 R1000-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 21012 N F(v max) 21601 N Horizontal force F(h) F(h normal) 353 N F(h max) 942 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 3967 Nm M(r max) 8127 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 173/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-92: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.25 Technical data, KP1-HC1500 R1200-2 4.25.1 Basic data, KP1-HC1500 R1200-2 Basic data KP1-HC1500 R1200-2 174/289 | www.kuka.com Number of axes 1 Pose repeatability A1 0.009 ° Weight approx. 391 kg Rated payload 1500 kg Protection rating (IEC 60529) IP67 Sound level < 78 dB (A) Mounting position Floor Default color Cover: KUKA Industrial Orange (RAL 2009); Booster frame: iron gray (RAL 7011); Pedestal: KUKA Industrial Orange (RAL 2009) Controller KR C4; KR C4 smallsize-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-HC1500 R1200-2 Footprint 800 mm x (980 mm + distance between face plates) Hole pattern: mounting surface for kinematic system R412x640 Hollow shaft diameter A1 - Counterbearing A1 68 mm Humidity class (EN 60204) - Classification of environmental conditions (EN 60721-3-3) 3K3 Ambient conditions Ambient temperature During operation 0 °C to 55 °C (273 K to 328 K) During storage/transportation -40 °C to 60 °C (233 K to 333 K) Connecting cables, KR C4 Cable designation Connector designation Motor cable KR C KR KP X7.1 - XM7 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 Interface on positioner Circular power connector, size 1, 6-pole XP7 - Resolver cable in operation with: Signal coupling circular connector, 17-pole XP7 Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 7 m, 15 m, 25 m Max. cable length 50 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables”. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 175/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Connecting cables, KR C5 Cable designation Connector designation Motor cable KR C KR KP Motor connector: XD20.1 XM7.1 - XM7 Interface on positioner Circular power connector, size 1, 6-pole Brake connector: XD10.1 XM7.1 Resolver cable in operation with: • • • • • • • • KR KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC QUANTEC-2 XP7 - Resolver cable in operation with: XP7 Signal coupling circular connector, 17-pole Xx • KR FORTEC • Additional RDC Ground conductor / equipotential bonding 16 mm2 - - - M8 ring cable lug at both ends Cable lengths 1.5 m, 2 m, 3 m, 4 m 5 m, 6 m, 7 m, 8 m, 9 m 10 m, 15 m, 20 m, 25 m Max. cable length 25 m Number of extensions 1 For detailed specifications of the connecting cables, see “Description of the connecting cables, KR C5”. 4.25.2 Axis data, KP1-HC1500 R1200-2 Axis data 176/289 | www.kuka.com Loading height 1240 mm Tool radius 1200 mm Motion range, axis 1 Infinite Motion range of axis 1 with energy supply system ±190 ° Turning time 180°, axis 1 2.7 s Turning time 360°, axis 1 4.4 s MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Mastering positions Mastering position A1 45 ° Direction of rotation The orientation of a rotational axis is defined on the motor side (drive): • “+” clockwise • “-” counterclockwise The motion directions and assignment of the axis are indicated in the following diagram. Fig. 4-93: Direction of rotation of axis, example Working envelope The following diagram shows the shape and size of the working envelope. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 177/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-94: Working envelope, side view, KP1-HC1500 R1200-2 4.25.3 1 Height: 1490 mm 2 Loading height: 1240 mm 3 Tool radius: 1200 mm Payloads, KP1-HC1500 R1200-2 Payloads Rated payload 1500 kg Maximum load torque A1 1472 Nm Mass moment of inertia A1 1059 kgm² Nominal distance to load center of gravity 178/289 | www.kuka.com Lx - Lyz 100 mm MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Technical data KP1-H-2; KP1-HC-2 Fig. 4-95: Load center of gravity 4.25.4 Foundation loads, KP1-HC1500 R1200-2 Foundation loads The specified forces and torques already include the payload and the inertia force (weight) of the positioner. Vertical force F(v) F(v normal) 21240 N F(v max) 21829 N Horizontal force F(h) F(h normal) 353 N F(h max) 942 N Tilting moment M(k) M(k normal) - M(k max) - Torque about axis 1 M(r) M(r normal) 3967 Nm M(r max) 8127 Nm *Tilting torque M(k max) only occurs during start-up or change of fixture. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 179/289 Technical data KP1-H-2; KP1-HC-2 Fig. 4-96: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. 4.26 Plates and labels Description The following plates, labels and signs are attached to the positioner. They must not be removed or rendered illegible. Illegible plates, labels and signs must be replaced. Fig. 4-97: Plates and labels on the positioner, example 180/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Item Description 1 Direction of translation/rotation The label shows the plus and minus directions of the corresponding translational/rotational axis. 2 Hot surface During operation of the robot, surface temperatures may be reached that could result in burn injuries. Protective gloves must be worn! 3 Secure the axis Before exchanging any motor, secure the corresponding axis through safeguarding by suitable means/devices to protect against possible movement. The axis can move. Risk of crushing! 4 Identification plate example Content according to Machinery Directive. The QR code contains a link to product information in KUKA Xpert. 5 Work on the positioner Before start-up, transportation or maintenance, read and follow the assembly and operating instructions. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 181/289 Technical data KP1-H-2; KP1-HC-2 Technical data KP1-H-2; KP1-HC-2 Item Description 6 Do not slacken screwed connection Do not slacken screwed connection! Observe safety instructions and assembly instructions! 4.27 REACH duty to communicate information acc. to Art. 33 As of June 2007, the Regulation (EC) 1907/2006 of the European Parliament and of the Council dated 18 December 2006 on the registration, evaluation and authorization of chemicals (REACH Regulation) is in force. Detailed REACH information can be found in the product information in KUKA Xpert. 4.28 Stopping distances General information • The stopping distance is the angle traveled by the positioner from the moment the stop signal is triggered until the positioner comes to a complete standstill. • Stop category: ‒ Stop category 0 » STOP 0 according to IEC 60204-1 • The values specified for Stop 0 are guide values determined by means of tests and simulation. They are average values. The actual stopping distances and stopping times may differ due to internal and external influences on the braking torque. It is therefore advisable to determine the exact stopping distances and stopping times where necessary under the real conditions of the actual positioner application. • Measuring technique The stopping distances were measured using the robot-internal measuring technique. • The wear on the brakes varies depending on the operating mode, robot application and the number of STOP 0 stops triggered. It is therefore advisable to check the stopping distance at least once a year. Description The table shows the stopping distances after a STOP 0 (category 0 stop) is triggered. Rated payload 500 kg 750 kg 1000 kg 1500 kg 30.00 ° 20.00 ° 25.00 ° 40.00 ° 0.50 s 0.40 s 0.50 s 0.60 s Stopping distance A1 Stopping time A1 182/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Planning KP1-H-2; KP1-HC-2 5 Planning 5.1 Information for planning In the planning and design phase, care must be taken regarding the functions or applications to be executed by the kinematic system. The following conditions can lead to premature wear. They necessitate shorter maintenance intervals and/or earlier exchange of components. In addition, the permissible operating parameters specified in the technical data must be taken into account and observed during planning. • Continuous operation near temperature limits or in abrasive environments • Continuous operation close to the performance limits, e.g. high rpm of an axis • High duty cycle of individual axes • Monotonous motion profiles, e.g. short, frequently recurring axis motions • External forces (process forces) acting on the robot If one or more of these conditions are to apply during operation of the kinematic system, KUKA Deutschland GmbH must be consulted. If the positioner reaches its corresponding operation limit or if it is operated near the limit for a period of time, the built-in monitoring functions come into effect and the positioner is automatically switched off. This protective function can limit the availability of the robot system. 5.2 Mounting base Description The positioner is fastened to the floor by means of resin-bonded anchors (chemical anchors). The mounting base consists of: • • • • Bedplate Welding strips Resin-bonded anchors (chemical anchors) Fastening elements This mounting variant requires a level and smooth surface on a concrete foundation with adequate load bearing capacity. The concrete foundation must be able to accommodate the forces occurring during operation. The minimum dimensions must be observed. The pedestal with mounting plate is screwed to the welding strips with fastening screws. The weld-on plate is aligned on the bedplate using leveling screws and lock nuts and then welded to the bedplate. The bedplate is bolted to the foundation with anchors. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 183/289 Planning KP1-H-2; KP1-HC-2 Fig. 5-1: Mounting base 1 Fastening elements 2 Bedplate 3 Welding strip (5x) 4 Resin-bonded anchor (4x) 5 Concrete foundation Grade of concrete for foundations When producing foundations from concrete, observe the load-bearing capacity of the ground and the country-specific construction regulations. There must be no layers of insulation or screed between the bedplate/ bedplates and the concrete foundation. The quality of the concrete must meet the requirements of the following standard: • C20/25 according to EN 206 WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. Dimensioned drawing The following illustration provides all the necessary information on the mounting base, together with the required foundation data. The specified foundation dimensions refer to the safe transmission of the foundation loads into the foundation and not to the stability of the foundation. 184/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Planning KP1-H-2; KP1-HC-2 Fig. 5-2: Mounting base, dimensioned drawing To ensure that the anchor forces are safely transmitted to the concrete foundation, the dimensions specified in the following illustration must be observed. Fig. 5-3: Foundation cross-section 1 Concrete foundation 2 Gap width at highest point of mounting base 3 Bedplate 4 Minimum concrete thickness 5 Minimum distance to edge Weld seams The bolt-on surface must be welded to the bedplate with the welding strips. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 185/289 Planning KP1-H-2; KP1-HC-2 Fig. 5-4: Mounting base, weld seams 1 Weld seams Weld seam quality The quality requirements for weld seams can be found in: (>>> 12.3 "Weld seams - Quality requirements" Page 282). These apply to the weld seams in the following task description unless other specifications are given. 5.3 Drive unit Description The following figure shows the dimensions and the hole pattern of the drive unit for the following positioners: • Positioner of the product family KP1-H-2 • Positioner of the product family KP1-HC-2 186/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Planning KP1-H-2; KP1-HC-2 Fig. 5-5: Dimensions, drive unit MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 187/289 Planning KP1-H-2; KP1-HC-2 A Positioner KP1-H-2 C D E F in mm KP1-H500 R800-2 KP1-H750 R800-2 KP1-H500 R1000-2 460 KP1-H750 R1000-2 KP1-H500 R1200-2 KP1-H750 R1200-2 1040 840 1240 1040 1440 1240 617 15 400 18 500 F G 15 400 18 500 417 KP1-H1000 R800-2 KP1-H1500 R800-2 KP1-H1000 R1000-2 428 KP1-H1500 R1000-2 KP1-H1000 R1200-2 KP1-H1500 R1200-2 A Positioner KP1-HC-2 1090 840 1290 1040 1490 1240 B C 667 D E in mm KP1-HC500 R800-2 KP1-HC750 R800-2 KP1-HC500 R1000-2 460 KP1-HC750 R1000-2 KP1-HC500 R1200-2 KP1-HC750 R1200-2 1040 840 1240 1040 1440 1240 617 417 KP1-HC1000 R800-2 KP1-HC1500 R800-2 KP1-HC1000 R1000-2 KP1-HC1500 R1000-2 428 KP1-HC1000 R1200-2 KP1-HC1500 R1200-2 5.4 B 1090 840 1290 1040 1490 1240 667 Counterbearing unit Description The following figure shows the dimensions and the hole pattern of the counterbearing unit for the following positioners: • Positioner of the product family KP1-HC-2 188/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Planning KP1-H-2; KP1-HC-2 Fig. 5-6: Dimensions, counterbearing unit Counterbearing unit Rated payload 500 kg A KP1-HC500 R800-2 840 1040 KP1-HC500 R1000-2 1040 1240 KP1-HC500 R1200-2 1240 1440 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 B in mm www.kuka.com | 189/289 Planning KP1-H-2; KP1-HC-2 5.5 Counterbearing unit Rated payload 750 kg A B KP1-HC750 R800-2 840 1040 KP1-HC750 R1000-2 1040 1240 KP1-HC750 R1200-2 1240 1440 Counterbearing unit Rated payload 1000 kg A B KP1-HC1000 R800-2 840 1090 KP1-HC1000 R1000-2 1040 1290 KP1-HC1000 R1200-2 1240 1490 Counterbearing unit Rated payload 1500 kg A B KP1-HC1500 R800-2 840 1090 KP1-HC1500 R1000-2 1040 1090 KP1-HC1500 R1200-2 1240 1090 in mm in mm in mm Dimensions of face plates Drive face plate, rated payload 500 kg - 750 kg The dimensions of the face plates on the drive for the rated payload 500 kg - 750 kg are specified in the following diagram (>>> Fig. 5-7): 190/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Planning KP1-H-2; KP1-HC-2 Fig. 5-7: Dimensions of face plate on drive, rated payload 500 kg 750 kg 1 Mounting borehole for support strip (optional) Drive face plate, payload 1000 kg - 1500 kg The dimensions of the face plates on the drive for the rated payload 1000 kg - 1500 kg are specified in the following diagram (>>> Fig. 5-8): MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 191/289 Planning KP1-H-2; KP1-HC-2 Fig. 5-8: Dimensions of face plate on drive, rated payload 1000 kg 1500 kg 1 Mounting borehole for support strip (optional) Counterbearing face plate The dimensions of the face plate on the counterbearing are specified in the following diagram (>>> Fig. 5-9). 192/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Planning KP1-H-2; KP1-HC-2 Fig. 5-9: Dimensions, face plate on counterbearing 1 5.6 Mounting borehole for support strip (optional) Counterbearing variants The following counterbearing variants are available: • Counterbearing, self-aligning with length compensation MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 193/289 Planning KP1-H-2; KP1-HC-2 • Counterbearing with length compensation The counterbearing has self-aligning bearings and a length compensation function for +/- 5 mm (>>> Fig. 5-10). Fig. 5-10: Counterbearing length compensation 5.7 1 Counterbearing, self-aligning with length compensation 2 Counterbearing with length compensation Connecting cables and interfaces Connecting cables The connecting cables comprise all the cables for transferring energy and signals between the positioner, the robot and the robot controller. Cable lengths of 7 m, 15 m and 25 m are available as standard. The maximum length of the connecting cables must not exceed 50 m. The maximum number of connectors is 1, i.e. a maximum of 2 connecting cables may be combined with each other. For the connecting cables, an additional ground conductor is always required to provide a low-resistance connection between the positioner and the control cabinet in accordance with DIN EN 60204. The ground conductor is connected via ring cable lugs. The threaded bolts for connecting the two ground conductors are located on the base frame of the positioner. The following points must be observed when planning and routing the connecting cables: • The bending radius for fixed routing must not be less than 150 mm for motor cables and 60 mm for data cables. • Protect cables against exposure to mechanical stress. • Route the cables without mechanical stress – no tensile forces on the connectors. • Cables are only to be installed indoors. • Observe the permissible temperature range (fixed installation) of 263 K (-10 °C) to 343 K (+55 °C). • Route the motor cables and the data cables separately in metal ducts. If necessary, take additional measures to ensure electromagnetic compatibility (EMC). 194/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 CAUTION Risk of injury due to tripping hazards Improper installation of cables can cause tripping hazards. Injuries or damage to property may result. • The connecting cables must be installed in such a way (e.g. cable ducts) as to prevent tripping hazards. • Potential tripping hazards must be marked accordingly. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 195/289 Planning KP1-H-2; KP1-HC-2 Planning KP1-H-2; KP1-HC-2 196/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 6 Transportation 6.1 Overview of transportation Transportation KP1-H-2; KP1-HC-2 Description It must be ensured that the positioner is stable while it is being transported. Before the positioner 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. The center of gravity must be taken into account during transportation. Remove any disruptive add-on parts (e.g. energy supply system) before transportation. WARNING The positioner may tip over during transportation. Risk of personal injury and damage to property. If the positioner is transported using lifting tackle (not included in the scope of supply), special care must be exercised to prevent it from tipping. Additional safeguarding measures must be taken. It is forbidden to pick up the positioner in any other way using a crane. WARNING Danger to life and limb due to non-authorized handling equipment If unsuitable handling equipment is used, the positioner may topple or be damaged during transportation. Death, severe injuries or damage to property may result. • Only use authorized handling equipment with a sufficient load-bearing capacity. • Only transport the positioner in the manner specified here. NOTICE There must be no fixtures and tools on the positioner during transportation, as material damage could otherwise result. The KUKA options (e.g. support strips) may remain on the positioner during transportation. Further information about transportation of the different positioners can be found in the following sections: • Transporting the drive unit (>>> 6.1.1 "Transporting the drive unit" Page 197) • Transporting the counterbearing unit (>>> 6.1.2 "Transportation of counterbearing unit" Page 199) 6.1.1 Transporting the drive unit Transport dimensions The dimensions for the positioner can be noted from the following drawings. The position of the center of gravity and the weight vary according to the specific configuration. The specified dimensions refer to the positioner without equipment. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 197/289 Transportation KP1-H-2; KP1-HC-2 Fig. 6-1: Transport dimensions, drive unit, example Positioner KP1-H-2 KP1-H500 R800-2 KP1-H750 R800-2 KP1-H500 R1000-2 KP1-H750 R1000-2 KP1-H500 R1200-2 KP1-H750 R1200-2 KP1-H1000 R800-2 KP1-H1500 R800-2 KP1-H1000 R1000-2 KP1-H1500 R1000-2 KP1-H1000 R1200-2 KP1-H1500 R1200-2 Positioner KP1-HC-2 KP1-HC500 R800-2 KP1-HC750 R800-2 KP1-HC500 R1000-2 KP1-HC750 R1000-2 KP1-HC500 R1200-2 KP1-HC750 R1200-2 KP1-HC1000 R800-2 KP1-HC1500 R800-2 KP1-HC1000 R1000-2 KP1-HC1500 R1000-2 KP1-HC1000 R1200-2 KP1-HC1500 R1200-2 198/289 | www.kuka.com A B C in mm 1040 1240 460 1440 600 1090 1290 428 1490 A B C in mm 1040 1240 460 1440 600 1090 1290 428 1490 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Transportation using lifting tackle The drive unit is transported using lifting tackle. The lifting tackle is attached to an M12 swivel eyebolt, which must be fitted at the top of the pedestal. All ropes of the lifting tackle must be long enough and routed in such a way that the anti-glare equipment is not damaged. Before transportation, check the position of the center of gravity. Fig. 6-2: Transportation using lifting tackle, drive unit, example 6.1.2 1 Crane 2 Lifting tackle (not included in scope of supply) 3 M12 swivel eyebolt 4 Drive unit Transportation of counterbearing unit Transport dimensions The dimensions for the positioner can be noted from the following drawings. The position of the center of gravity and the weight vary according to the specific configuration. The specified dimensions refer to the positioner without equipment. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 199/289 Transportation KP1-H-2; KP1-HC-2 Transportation KP1-H-2; KP1-HC-2 Fig. 6-3: Transport dimensions, counterbearing unit, example Positioner A B C in mm KP1-HC500 R800-2 KP1-HC750 R800-2 KP1-HC1000 R800-2 840 KP1-HC1500 R800-2 KP1-HC500 R1000-2 KP1-HC750 R1000-2 KP1-HC1000 R1000-2 1040 378 600 KP1-HC1500 R1000-2 KP1-HC500 R1200-2 KP1-HC750 R1200-2 KP1-HC1000 R1200-2 1240 KP1-HC1500 R1200-2 Transportation using lifting tackle The counterbearing unit is transported using lifting tackle. The lifting tackle is attached to an M12 swivel eyebolt, which must be fitted at the top of the pedestal. All ropes of the lifting tackle must be long enough and routed in such a way that the anti-glare equipment is not damaged. Before transportation, check the position of the center of gravity. 200/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Transportation KP1-H-2; KP1-HC-2 Fig. 6-4: Transportation using lifting tackle, counterbearing unit, example 1 Crane 2 Lifting tackle (not included in scope of supply) 3 M12 swivel eyebolt 4 Counterbearing unit MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 201/289 Transportation KP1-H-2; KP1-HC-2 202/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 7 Start-up and recommissioning The procedure for start-up and recommissioning comprises the following steps: Description Installation with mounting base Information KP1-H-2 Start-up (mounting base) (>>> 7.1 "Starting up the positioner KP1-H-2 (mounting base)" Page 203) KP1-HC-2 Start-up (mounting base) (>>> 7.2 "Starting up the positioner KP1-HC-2 (mounting base)" Page 212) 7.1 Starting up the positioner KP1-H-2 (mounting base) Description The mounting base is used for installing positioners on a foundation. It is fastened to a suitable concrete foundation using a bedplate / bedplates and resin-bonded anchors. The positioner is mounted on the bedplate using leveling screws and then welded by means of welding strips. If the surface of the concrete foundation is not sufficiently smooth and even, the differences must be evened out with a suitable leveling compound. When using a Dynamic Set and resin-bonded anchors, use only components and resin capsules from the same manufacturer. No diamond tools or core drills may be used for drilling the anchor holes; for preference, drilling tools supplied by the anchor manufacturer are to be used. The manufacturer’s instructions for the use of resin-bonded anchors must also be observed. The installation and start-up of the robot controller, the tools mounted and the applications are not described here. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 203/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 Fig. 7-1: Mounting base, weld seams 1 Weld seams Equipment The following equipment is required: 204/289 | www.kuka.com Designation Article number Lifting tackle with adequate carrying capacity - Crane with adequate carrying capacity - Swivel eyebolt - Drill with a ø 18 mm bit - Setting tool approved by the anchor manufacturer - Laser tracker (optional) - Welding device - Leveling device - Spirit level - Set of combination wrenches 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 17; 19 mm 22; 24; 27; 30; 32; 36; 46 mm - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10; 12; 14; 16; 20; 24; 30 mm - Torque wrench min. 2 to 20 Nm - MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Designation Article number Torque wrench min. 400 to 700 Nm - Material The following material is required: Designation Article number Quantity Foundation fixture KP1-H-2 0000-382-461 1 Filler metal - - Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Weld seam quality The quality requirements for weld seams can be found in: (>>> 12.3 "Weld seams - Quality requirements" Page 282). These apply to the weld seams in the following task description unless other specifications are given. Precondition • • • • • • • • The installation site is accessible with a crane. The positioner is in the transport position. The substructure has been checked for sufficient safety. The concrete foundation must have the required dimensions and cross-section. The surface of the foundation must be smooth and even. Have the leveling compound readily at hand. Any tools or other system components which would hinder the work have been removed. The connecting cables and ground conductors are routed to the positioner and installed. Work safety WARNING Danger to life and limb due to unintended positioner motions Unintended positioner motions may result in death, severe injuries and damage to property. • Secure the positioner by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 205/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 WARNING Danger to life and limb due to non-authorized handling equipment If unsuitable handling equipment is used, the positioner may topple or be damaged during transportation. Death, severe injuries or damage to property may result. • Only use authorized handling equipment with a sufficient load-bearing capacity. • Only transport the positioner in the manner specified here. WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. WARNING Danger to life and limb due to toppling positioner If the positioner is not mounted on the foundation plate, it may topple over. Death, severe injuries or damage to property may result. • Secure the positioner against toppling throughout the entire installation procedure. CAUTION Risk of injury due to tripping hazards Improper installation of cables can cause tripping hazards. Injuries or damage to property may result. • The connecting cables must be installed in such a way (e.g. cable ducts) as to prevent tripping hazards. • Potential tripping hazards must be marked accordingly. 7.1.1 Installing the mounting base Procedure 1. Determine the position of the drive unit in accordance with the system layout. 2. Set the bedplate down on the foundation in its installation position (>>> 7.2.1 "Installing the mounting base" Page 215). 3. Check the surface of the concrete foundation: • If the surface is sufficiently smooth and even, continue with step 9. • If the surface is not sufficiently smooth and even, continue with step 4. If the surface is not sufficiently smooth and even, continue with 4. Lift the positioner with a crane. 5. Apply sufficient leveling compound to the underside of the bedplates (toothed spatula). The area under the hexagon bolt for robot fastening must be kept free from leveling compound. 6. Set the positioner down and align it. 206/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 7. Remove excess leveling compound. The maximum height of the leveling compound must not be exceeded. Observe the manufacturer’s specifications. 8. Allow the leveling compound to set in accordance with the manufacturer’s instructions. 9. Drill 3 anchor holes in accordance with the manufacturer’s specifications and fit the anchors as specified in the instructions for use. The instructions for use are enclosed with the anchors and must be followed precisely. Fig. 7-2: Installing the bedplate 7.1.2 1 Bedplate 2 Resin-bonded anchor Installing the positioner Procedure • • • • • • • • • • Bring the positioner to the installation site with the crane. Lift the positioner approx. 10 cm by crane. Clean the lower mounting surface on the positioner. Screw 3 thrust pins (leveling screws) incl. 3 type 1 M24 hexagon nuts into the lower plate of the booster frame to a dimension of approx. 56 mm and hand-tighten and lock the hexagon nuts (>>> Fig. 7-3). Place 1 thrust plate on each thrust pin (leveling screw), fasten with 1 M12x100-8.8-A2K hexagon bolt and hand-tighten. Carefully place the positioner on the bedplate. Turn the 3 M12x100-8.8-A2K hexagon bolts and the 3 type 1 M24 hexagon nuts to raise them a little. Align the positioner vertically by turning the 3 thrust pins (leveling screws) and lock them with the 3 hexagon nuts. As a leveling aid, place a spirit level on the upper plate of the booster frame. The distance between the upper edge of the lower plate of the booster frame and the upper edge of the bedplate must be approx. 50 mm. Tighten the 3 M12x100-8.8-A2K hexagon bolts. Increase the tightening torque to the specified value in several stages. Weld all 3 thrust plates circumferentially to the extent they are accessible. Place welding strips on the bedplate and on the booster frame. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 207/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 • Weld the welding strips along the long welding strip edges to the bedplate at the bottom and to the booster frame at the top. • Remove the lifting tackle. Fig. 7-3: Foundation plate, welding strips, height adjustment, weld seam 7.1.3 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) 7 Thrust plate (3x) 8 Upper edge of the lower plate of the booster frame Connecting the connecting cables Procedure 1. Connect the resolver cable: • KR C4: Resolver cable XP7 to motor connection XP7 • KR C5: Resolver cable XP7 to motor connection XP7 in operation with: ‒ ‒ ‒ ‒ 208/289 | www.kuka.com KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 ‒ KR CYBERTECH nano ‒ KR CYBERTECH nano-2 ‒ KR QUANTEC ‒ KR QUANTEC-2 • KR C5: Resolver cable Xx to motor connection XP7 in operation with: ‒ KR FORTEC ‒ Additional RDC 2. Connect motor cables: Motor cable X7.1 to connection XM7 When connecting the motor cable connectors, it must be ensured that the connectors are locked correctly on the positioner. Correct locking is indicated by an audible click. It is indicated optically by the fact that the red rings on each of the locking buttons are not visible and are pushed in completely. 3. Check the equipotential bonding in accordance with VDE 0100 and EN 60204-1. Further information is contained in the operating and assembly instructions of the robot controller. Fig. 7-4: Connecting cables, example 7.1.4 1 Resolver cable XP7.1 2 Motor cable XM7.1 Machine data Description During start-up, the positioner must be configured with the aid of WorkVisual. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 209/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 WARNING The positioner must not be moved if incorrect machine data are loaded. Personal injuries or damage to property may result in this case. Further information about WorkVisual is contained in the WorkVisual documentation and about configuration of the machine data in the operating and assembly instructions Configuration of Kinematic Systems. Further information is contained in the operating and programming instructions for the KUKA System Software (KSS). 7.1.5 Mastering the positioner Description The mastering of positioners is analogous to that of robot axes. During mastering, the positioner is moved to the mechanical zero position, and the encoder value for each axis is saved. In this way, the mechanical zero position and the electronic zero position are made to coincide. When mastering positioners, the axes must be mastered in ascending order. Mastering methods The positioner can be mastered using one of the following methods: • With the EMD • With the dial gauge EMD mastering is recommended. Further information is contained in the operating and programming instructions. Pre-mastering position The pre-mastering position is a prerequisite for every mastering procedure carried out with the EMD. Each axis is moved so that the probe pin is positioned in front of the reference notch. When mastering with the EMD, an axis is always moved to the mechanical zero position from “+” to “-”. 210/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Start-up and recommissioning KP1-H-2; KP1-HC-2 Fig. 7-5: Mastering run 1 Pre-mastering position 5 Gauge cartridge 2 Motion direction of axis 6 Probe pin 3 Mechanical zero position 7 EMD 4 Reference notch Position of the gauge cartridges The EMD is fastened to the corresponding gauge cartridge. The following figure (>>> Fig. 7-6) shows the positions of the gauge cartridges. Fig. 7-6: Position of the gauge cartridges 1 Gauge cartridge A1 Mechanical zero position The following illustration shows the electronic zero position of the positioner. The mechanical zero position of A1 is given when A1 has moved 45° in the plus direction (>>> Fig. 7-7). MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 211/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Fig. 7-7: Mechanical zero position 7.1.6 Concluding work The following concluding work must be carried out: • • • • Check that the weld seams meet the quality requirements. Document the welding operation. If applicable, mount the tool. Start up the robot system in accordance with the chapter “Start-up and recommissioning” in the operating instructions for the robot controller. • Put the robot system into operation in accordance with the chapter “Start-up and recommissioning” of the operating and programming instructions for the KUKA System Software (KSS). 7.2 Starting up the positioner KP1-HC-2 (mounting base) Description The mounting base is used for installing positioners on a foundation. It is fastened to a suitable concrete foundation using a bedplate / bedplates and resin-bonded anchors. The positioner is mounted on the bedplate using leveling screws and then welded by means of welding strips. If the surface of the concrete foundation is not sufficiently smooth and even, the differences must be evened out with a suitable leveling compound. When using a Dynamic Set and resin-bonded anchors, use only components and resin capsules from the same manufacturer. No diamond tools or core drills may be used for drilling the anchor holes; for preference, drilling tools supplied by the anchor manufacturer are to be used. The manufacturer’s instructions for the use of resin-bonded anchors must also be observed. The installation and start-up of the robot controller, the tools mounted and the applications are not described here. 212/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Start-up and recommissioning KP1-H-2; KP1-HC-2 Fig. 7-8: Mounting base, weld seams 1 Weld seams Equipment The following equipment is required: Designation Article number Lifting tackle with adequate carrying capacity - Crane with adequate carrying capacity - 2 swivel eyebolts - Drill with a ø 18 mm bit - Setting tool approved by the anchor manufacturer - Welding device - Leveling device - Spirit level - Set of combination wrenches 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 17; 19 mm 22; 24; 27; 30; 32; 36; 46 mm - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10; 12; 14; 16; 20; 24; 30 mm - Torque wrench min. 2 to 20 Nm - MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 213/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Designation Article number Torque wrench min. 400 to 700 Nm - Material The following material is required: Designation Article number Quantity Foundation fixture KP1-HC-2 0000-382-462 1 Filler metal - - Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Weld seam quality The quality requirements for weld seams can be found in: (>>> 12.3 "Weld seams - Quality requirements" Page 282). These apply to the weld seams in the following task description unless other specifications are given. Precondition • • • • • • • • The installation site is accessible with a crane. The positioner is in the transport position. The substructure has been checked for sufficient safety. The concrete foundation must have the required dimensions and cross-section. The surface of the foundation must be smooth and even. Have the leveling compound readily at hand. Any tools or other system components which would hinder the work have been removed. The connecting cables and ground conductors are routed to the positioner and installed. Work safety WARNING Danger to life and limb due to unintended positioner motions Unintended positioner motions may result in death, severe injuries and damage to property. • Secure the positioner by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 214/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 WARNING Danger to life and limb due to non-authorized handling equipment If unsuitable handling equipment is used, the positioner may topple or be damaged during transportation. Death, severe injuries or damage to property may result. • Only use authorized handling equipment with a sufficient load-bearing capacity. • Only transport the positioner in the manner specified here. WARNING Danger to life and limb due to incorrect mounting If not mounted correctly, the kinematic system may topple over or fall down. Death, severe injury or damage to property may result. • Only install the kinematic system using the mounting base or machine frame mounting. • The stability must be ensured by the integrator or start-up technician. WARNING Danger to life and limb due to toppling positioner If the positioner is not mounted on the foundation plate, it may topple over. Death, severe injuries or damage to property may result. • Secure the positioner against toppling throughout the entire installation procedure. CAUTION Risk of injury due to tripping hazards Improper installation of cables can cause tripping hazards. Injuries or damage to property may result. • The connecting cables must be installed in such a way (e.g. cable ducts) as to prevent tripping hazards. • Potential tripping hazards must be marked accordingly. 7.2.1 Installing the mounting base Procedure 1. Determine the position of the drive unit and counterbearing unit according to the system layout. 2. Set the bedplate down on the foundation in its installation position (>>> 7.2.1 "Installing the mounting base" Page 215). 3. Check the surface of the concrete foundation: • If the surface is sufficiently smooth and even, continue with step 9. • If the surface is not sufficiently smooth and even, continue with step 4. If the surface is not sufficiently smooth and even, continue with 4. Lift the positioner with a crane. 5. Apply sufficient leveling compound to the underside of the bedplates (toothed spatula). The area under the hexagon bolt for robot fastening must be kept free from leveling compound. 6. Set the positioner down and align it. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 215/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 7. Remove excess leveling compound. The maximum height of the leveling compound must not be exceeded. Observe the manufacturer’s specifications. 8. Allow the leveling compound to set in accordance with the manufacturer’s instructions. 9. Check that both bedplates are aligned horizontally. 10. Drill 3 anchor holes in accordance with the manufacturer’s specifications and fit the anchors as specified in the instructions for use. The instructions for use are enclosed with the anchors and must be followed precisely. Fig. 7-9: Installing the bedplate 7.2.2 1 Bedplate 2 Resin-bonded anchor Installing the positioner Procedure 1. 2. 3. 4. 5. 6. 7. 8. 216/289 | www.kuka.com Bring the positioner to the installation site with the crane. Lift the positioner approx. 10 cm by crane. Clean the lower mounting surface on the positioner. For each positioner, screw 3 thrust pins (leveling screws) incl. 3 type 1 M24 hexagon nuts into the lower plate of the booster frame to a dimension of approx. 56 mm and hand-tighten and lock the hexagon nuts (>>> Fig. 7-11). Place 1 thrust plate on each thrust pin (leveling screw), fasten with 1 M12x100-8.8-A2K hexagon bolt and hand-tighten. Carefully place the positioner on the bedplate. Turn the 3 M12x100-8.8-A2K hexagon bolts and 3 M24 hexagon nuts to raise them a little. Align the positioner vertically by turning the 3 thrust pins (leveling screws). As a leveling aid, place a spirit level on the upper plate of the booster frame. The distance between the upper edge of the lower plate of the booster frame and the upper edge of the bedplate must be approx. 50 mm. Align the drive unit and counterbearing unit parallel to one another. The face plates must be installed exactly parallel to one another at the desired distance. Take the length compensation into consideration so that it can be implemented with ±5 mm. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Start-up and recommissioning KP1-H-2; KP1-HC-2 Fig. 7-10: Counterbearing length compensation 1 Counterbearing, self-aligning with length compensation 2 Counterbearing with length compensation 9. Adjust the alignment of the rotational axes relative to one another by shifting the drive unit and counterbearing unit on their respective bedplates and by further turning the 3 thrust pins (leveling screws). The radial offset must not exceed 0.1 mm per 1 m distance between face plates (coaxiality of the rotational axes Ø0.1 mm per 1 m distance between face plates). The parallelism of the face plates and the radial offset of the rotational axes depend on one another, which means that precise alignment is required. 10. On completion of the adjustment tasks on the drive unit and counterbearing unit, lock the 3 thrust pins (leveling screws) with the 3 M24 hexagon nuts. 11. Tighten the 3 M12x100-8.8-A2K hexagon bolts. Increase the tightening torque to the specified value in several stages. 12. Weld all 3 thrust plates circumferentially to the extent they are accessible. 13. Place welding strips on the bedplate and on the booster frame. 14. Weld the welding strips along the long welding strip edges to the bedplate at the bottom and to the booster frame at the top. 15. Remove the lifting tackle. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 217/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Fig. 7-11: Foundation plate, welding strips, height adjustment, weld seam 7.2.3 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) 7 Thrust plate (3x) 8 Upper edge of the lower plate of the booster frame Connecting the connecting cables Procedure 1. Connect the resolver cable: • KR C4: Resolver cable XP7 to motor connection XP7 • KR C5: Resolver cable XP7 to motor connection XP7 in operation with: ‒ ‒ ‒ ‒ ‒ ‒ ‒ 218/289 | www.kuka.com KR KR KR KR KR KR KR AGILUS-1 AGILUS-2 CYBERTECH CYBERTECH-2 CYBERTECH nano CYBERTECH nano-2 QUANTEC MA KP1-H-HC-2 V2 | Issued: 10.10.2022 ‒ KR QUANTEC-2 • KR C5: Resolver cable Xx to motor connection XP7 in operation with: ‒ KR FORTEC ‒ Additional RDC 2. Connect motor cables: Motor cable X7.1 to connection XM7 When connecting the motor cable connectors, it must be ensured that the connectors are locked correctly on the positioner. Correct locking is indicated by an audible click. It is indicated optically by the fact that the red rings on each of the locking buttons are not visible and are pushed in completely. 3. Check the equipotential bonding in accordance with VDE 0100 and EN 60204-1. Further information is contained in the operating and assembly instructions of the robot controller. Fig. 7-12: Connecting cables, example 7.2.4 1 Resolver cable XP7.1 2 Motor cable XM7.1 Machine data Description During start-up, the positioner must be configured with the aid of WorkVisual. WARNING The positioner must not be moved if incorrect machine data are loaded. Personal injuries or damage to property may result in this case. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 219/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 Further information about WorkVisual is contained in the WorkVisual documentation and about configuration of the machine data in the operating and assembly instructions Configuration of Kinematic Systems. Further information is contained in the operating and programming instructions for the KUKA System Software (KSS). 7.2.5 Mastering the positioner Description The mastering of positioners is analogous to that of robot axes. During mastering, the positioner is moved to the mechanical zero position, and the encoder value for each axis is saved. In this way, the mechanical zero position and the electronic zero position are made to coincide. When mastering positioners, the axes must be mastered in ascending order. Mastering methods The positioner can be mastered using one of the following methods: • With the EMD • With the dial gauge EMD mastering is recommended. Further information is contained in the operating and programming instructions. Pre-mastering position The pre-mastering position is a prerequisite for every mastering procedure carried out with the EMD. Each axis is moved so that the probe pin is positioned in front of the reference notch. When mastering with the EMD, an axis is always moved to the mechanical zero position from “+” to “-”. Fig. 7-13: Mastering run 220/289 | www.kuka.com 1 Pre-mastering position 5 Gauge cartridge 2 Motion direction of axis 6 Probe pin 3 Mechanical zero position 7 EMD MA KP1-H-HC-2 V2 | Issued: 10.10.2022 4 Reference notch Position of the gauge cartridges The EMD is fastened to the corresponding gauge cartridge. The following figure (>>> Fig. 7-14) shows the positions of the gauge cartridges. Fig. 7-14: Position of the gauge cartridges 1 Gauge cartridge A1 Mechanical zero position The following illustration shows the electronic zero position of the positioner. The mechanical zero position of A1 is given when A1 has moved 45° in the plus direction (>>> Fig. 7-15). Fig. 7-15: Mechanical zero position 7.2.6 Concluding work The following concluding work must be carried out: • • • • Check that the weld seams meet the quality requirements. Document the welding operation. If applicable, mount the tool. Start up the robot system in accordance with the chapter “Start-up and recommissioning” in the operating instructions for the robot controller. • Put the robot system into operation in accordance with the chapter “Start-up and recommissioning” of the operating and programming instructions for the KUKA System Software (KSS). MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 221/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 7.3 Description of the connecting cables, KR C4 Configuration The connecting cables are used to transfer power and signals between the positioner, the robot and the robot controller. The connecting cables comprise: • Motor cable • Resolver cable, depending on the manipulator used Interface Cable designation Connector designation Interface on positioner KP KR KRC Motor cable A1 XM7.1 - X7.1 Circular power connector, size 1, 6-pole Resolver cable A1 XP7.1 X7 - Signal coupling circular connector, 17-pole Ground conductor / equipotential bonding 16 mm2 M8 ring cable lug Fig. 7-16: Connecting the robot controller, example 222/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 7.3.1 Start-up and recommissioning KP1-H-2; KP1-HC-2 Description of the Motor cable Cable overview Fig. 7-17: Motor cable 1 X... 2 XM... Connector pin allocation Connector pin allocation X... Connector pin allocation XM... The contact assignment on the connector side is shown in each case. Wiring diagram X... Pin Description XM... Pin 1 U 1 2 V 2 3 W 6 PE Ground conductor PE 11 Brake + 4 12 Brake - 5 Shield 11, 12, Housing MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Shield 4, 5, Shield 1, 2, 3, 11, 12 Shield 1, 2, 4, 5, 6 Housing www.kuka.com | 223/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 7.3.2 Description of the Control cable, single axis Resolver cable, KR QUANTEC The resolver cable is used with manipulators from the following product families: • • • • • • • KR KR KR KR KR KR KR QUANTEC QUANTEC QUANTEC QUANTEC QUANTEC QUANTEC QUANTEC pro extra prime ultra nano press PA Cable overview Fig. 7-18: Control cable, single axis 1 X.. 2 XP.. Connector pin allocation Connector pin allocation X.. Connector pin allocation XP.. The contact assignment on the connector side is shown in each case. Wiring diagram 224/289 | www.kuka.com X.. Pin Description XP.. Pin 9 Temp. 9 8 Temp. 8 4 Shield 9, 8 4 7 R2 7 10 R1 10 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 7.3.3 X.. Pin Description XP.. Pin 2 S4 2 1 S2 1 12 S3 12 11 S1 11 5 Shield 12, 11 5 3 Shield 2, 1 3 6 Shield 7, 10 6 Description of the Resolver cable Resolver cable, KR FORTEC The data cable is used with manipulators from the following product families: • KR 360 FORTEC • KR 500 FORTEC • KR 600 FORTEC Cable overview Fig. 7-19: Resolver cable 1 X... 2 XP... Connector pin allocation Connector pin allocation X... Connector pin allocation XP... The contact assignment on the connector side is shown in each case. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 225/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 Wiring diagram X... Pin Description XP... Pin 8 Temp. 9 7 Temp. 8 Shield 9, 8 4 6 R2 7 5 R1 10 4 S4 2 3 S2 1 2 S3 12 1 S1 11 Housing Shield 8.7 Shield 12, 11 5 Shield 2, 1 3 Shield 7, 10 6 Shield 6, 5 Shield 4, 3 Shield 2, 1 7.3.4 Description of the Resolver cable extension Resolver cable, KR AGILUS, KR CYBERTECH, KR CYBERTECH nano, KR IONTEC, KR QUANTEC-2 The data cable is used with manipulators from the following product families: • • • • • • • • • • • • • • • • • • 226/289 | www.kuka.com KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR AGILUS sixx AGILUS fivve AGILUS 3 AGILUS 4 AGILUS CYBERTECH nano CYBERTECH nano-2 CYBERTECH ARC nano CYBERTECH nano-2 ARC CYBERTECH CYBERTECH-2 CYBERTECH ARC CYBERTECH-2 ARC IONTEC QUANTEC-2 QUANTEC-2 PA FORTEC-2 FORTEC-2 ultra MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Start-up and recommissioning KP1-H-2; KP1-HC-2 Cable overview Fig. 7-20: Resolver cable extension 1 XP.. 2 X.. Connector pin allocation Connector pin allocation XP.. Connector pin allocation X.. The contact assignment on the connector side is shown in each case. Wiring diagram XP.. Pin Description 11 S1 12 S3 1 S2 2 S4 10 R1 7 R2 8 Temp. 9 Temp. 4 Shield 8, 9 6 Shield 10, 7 3 Shield 1, 2 5 Shield 11, 12 X.. Pin Twisted 11 12 Twisted 1 2 Twisted 10 7 Twisted 8 9 Shield 11, 12 Housing Shield 1, 2 Shield 10, 7 Shield 8, 9 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 227/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 7.3.5 Description of the ground conductor Fig. 7-21: Connecting cable, ground conductor 7.4 1 Ground conductor 6 Conical spring washer 2 Hexagon nut 7 Robot 3 Conical spring washer 8 Setscrew 4 2x plain washer 9 Ground conductor connection Ring cable lug 5 Hexagon nut 10 Ground sign Description of the connecting cables, KR C5 Configuration The connecting cables are used to transfer power and signals between the positioner, the robot and the robot controller. The connecting cables comprise: • Motor cable XD20.1/XD10.1 - XM7 ‒ Motor connector XD20.1 - XM7.1 ‒ Brake connector: XD10.1 - XM7.1 • Data cable X31.1, X21.1 - X31.1 Interface For connection of the connecting cables between the positioner, the robot and the robot controller, the following connectors are available at the interfaces: Cable designation Connector designation robot controller - positioner Interface on positioner Motor cable Motor connector: XD20.1 - XM7.1 Circular power connector, size 1, 6-pole Brake connector: XD10.1 - XM7.1 Data cable XF21 - XF31 (X31.1) Han® Q12 with flange Ground conductor / equipotential bonding 16 mm2 (optional) - M8 ring cable lug at both ends 228/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Standard connecting cable The following diagram (>>> Fig. 7-22) provides an overview of the connecting cables. The axis specifications in this illustration are examples. If the positioner is operated with a KR C5 and a robot, a drive box for external axes is required. Further information is contained in the operating and assembly instructions of the robot controller. Fig. 7-22: Connecting cables, overview, KR C5 (example) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 229/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 7.4.1 Description of the Motor cable Cable overview Fig. 7-23: Motor cable 1 XD20.x / XD10.x 2 XDx Connector pin allocation Connector pin allocation XD20.x / XD10.x Connector pin allocation XDx The contact assignment on the connector side is shown in each case. Wiring diagram XD20.x / XD10.x Pin 230/289 | www.kuka.com Description XDx Pin 1 U 1 2 V 2 3 W 6 PE PE PE MA KP1-H-HC-2 V2 | Issued: 10.10.2022 XD20.x / XD10.x Pin 7.4.2 Description XDx Pin B:2 br_+ 4 B:4 br_GND 5 Housing Shield B2, B4 Shield 4, 5 Housing Description of the Data cable Cable overview Fig. 7-24: Data cable 1 X21.1 2 X31 Connector pin allocation Connector pin allocation X21.1 Connector pin allocation X31 The contact assignment on the connector side is shown in each case. Wiring diagram X21.1 Pin Description X31 Pin 9 TPFO_P 9 11 TPFO_N 11 Housing Shield 9, 11 10 TPFO_P 10 12 TPFO_N 12 Housing Shield 10, 12 3 GND MA KP1-H-HC-2 V2 | Issued: 10.10.2022 3 www.kuka.com | 231/289 Start-up and recommissioning KP1-H-2; KP1-HC-2 Start-up and recommissioning KP1-H-2; KP1-HC-2 7.4.3 X21.1 Pin Description X31 Pin 2 24 V 2 Housing Shield, all pins Housing Description of the ground conductor Fig. 7-25: Connecting cable, ground conductor 232/289 | www.kuka.com 1 Ground conductor 6 Conical spring washer 2 Hexagon nut 7 Robot 3 Conical spring washer 8 Setscrew 4 2x plain washer 9 Ground conductor connection Ring cable lug 5 Hexagon nut 10 Ground sign MA KP1-H-HC-2 V2 | Issued: 10.10.2022 8 Maintenance Only maintenance and repair work described in this document may be performed. Work that exceeds this scope may only be carried out by personnel specially trained by KUKA. Information about KUKA College and its training program can be found at college.kuka.com or can be obtained directly from our subsidiaries. In the case of support and repair services provided by KUKA, KUKA Service must be informed in advance about potential contamination or hazards. Non-compliance nullifies warranty and liability claims. 8.1 Maintenance overview Description The maintenance intervals given in the tables are valid for the operating conditions specified in the technical data (>>> 4 "Technical data" Page 33). KUKA must be consulted in the event of deviations in working conditions or the use of special functions or applications. Further information can be found in the section “Information for planning” (>>> 5.1 "Information for planning" Page 183). A general inspection of the positioner is recommended after 7 years or if its use is changed. Please contact KUKA Service for this. If the positioner is fitted with a KUKA energy supply system (optional), additional maintenance work must be carried out. NOTICE Only auxiliary substances and consumables approved by KUKA Deutschland GmbH may be used. Non-approved auxiliary substances and consumables may cause premature wear and failure of assemblies. Precondition • The positioner controller must be switched off and secured to prevent unauthorized persons from switching it on again. • The power cable must be de-energized. • The positioner and the installed tools and fixtures must be mechanically secured to prevent unintentional motions. • Remove the tools and any additional items of equipment if they impede maintenance work. WARNING When work is carried out on the positioner, turn the main switch on the control cabinet to “OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again. If oil temperatures of more than 60 °C (333 K) are reached during operation, shorter maintenance intervals must be observed; for this, consultation with KUKA Deutschland GmbH is necessary. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 233/289 Maintenance KP1-H-2; KP1-HC-2 Maintenance KP1-H-2; KP1-HC-2 8.1.1 Maintenance table Maintenance symbols The overview may contain maintenance symbols that are not relevant for the maintenance work on this product. The maintenance illustrations provide an overview of the relevant maintenance work. Oil change Lubricate with grease gun Lubricate with brush Lubricate with spray grease Tighten screw/nut Check component, visual inspection Clean component Exchange battery Exchange component Check toothed belt tension Fig. 8-1: Maintenance diagram 234/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Interval Item Once only, af- 1 ter 100 h Task Check the holding-down bolts with the torque wrench. Exchange damaged bolts and washers. Retighten if necessary. Mark bolts after inspection. 6 months 1 Check the markings of the holding-down bolts for any changes. Visual inspection for corrosion and damage. If a marking has changed, replace the affected bolt and washer with new ones. After 100 h, check these bolts with the torque wrench. Mark bolts after inspection. 6 months - Check the entire robot, including the connecting cables and electrical installations, for foreign bodies, oil leaks and damage. If any damage is discovered, take the positioner out of operation and inform KUKA Service. 7 years - Have gear unit A1 inspected by KUKA Service and exchanged if necessary. Axis A1 is maintenance-free with regard to oil change. Up-to-date safety data sheets must be requested from the manufacturers of auxiliary and operating materials. Further information about the auxiliary substances and consumables used can be found under: (>>> 12.2 "Auxiliary and operating materials used" Page 282) 8.2 Cleaning the positioner Description The positioner must be cleaned in compliance with the instructions given here in order to prevent damage. These instructions only refer to the positioner. Equipment The following equipment is required: Designation Article number Permissible cleaning tools (e.g. cloths, brushes) - Material The following material is required: Designation Article number Quantity Cleaning agent solvent-free, water-soluble, non-flammable, non-aggressive, no steam, no refrigerants - - Precondition • The robot controller is switched off. • The positioner is freely accessible. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 235/289 Maintenance KP1-H-2; KP1-HC-2 Maintenance KP1-H-2; KP1-HC-2 Work safety NOTICE The following must be taken into consideration when carrying out cleaning work (material damage may otherwise result): • Cleaning must be in accordance with the corresponding cleaning instructions. • Do not use high-pressure cleaners. • Compressed air must not be used to clean bearing and sealing points. • It must be ensured that no cleaning agent enters electrical or mechanical system components. 8.2.1 Cleaning Procedure 1. Shut down the positioner. 2. If necessary, shut adjacent system components down and lock them. 3. Remove enclosures if this is necessary in order to carry out the cleaning work. 4. Clean the positioner. 5. Fully remove all cleaning agents from the positioner. 6. Clean any areas of corrosion and reapply corrosion protection. 7. Install any safety equipment that has been removed. 8. Put back in place any enclosures that have been removed. 8.2.2 Concluding work The following concluding work must be carried out: • Remove cleaning agents and equipment from the workspace of the positioner. • Dispose of cleaning agents in accordance with the pertinent regulations. • Replace any damaged or illegible plates and covers. • Check any protective and safety equipment that had been removed for correct operation. 236/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 9 Repair KP1-H-2; KP1-HC-2 Repair Only maintenance and repair work described in this document may be performed. Work that exceeds this scope may only be carried out by personnel specially trained by KUKA. Information about KUKA College and its training program can be found at college.kuka.com or can be obtained directly from our subsidiaries. In the case of support and repair services provided by KUKA, KUKA Service must be informed in advance about potential contamination or hazards. Non-compliance nullifies warranty and liability claims. 9.1 Exchanging motor A1; rated payload 500 kg and 750 kg Description The following sections describe the procedure for exchanging the motor on a positioner. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Hexagon socket set - Torque wrench min. 20 Nm to 100 Nm - Torque wrench min. 2 Nm to 20 Nm - SEMD/MEMD mastering kit 0000-228-936 Material The following material is required: Designation Article number Quantity SPP motor 2,5kW L0 ME 500 - 750kg 0000-362-745 1 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 237/289 Repair KP1-H-2; KP1-HC-2 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The positioner controller must be switched off and secured to prevent unauthorized persons from switching it on again. • The power cable must be deenergized. • The positioner must be mechanically secured to prevent unintentional motions. • There is no fixture and no tool mounted on the positioner. Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. WARNING Danger to life and limb due to unintended positioner motions Unintended positioner motions may result in death, severe injuries and damage to property. • Secure the positioner by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. CAUTION Risk of burns on hot surfaces High motor surface temperatures immediately after the positioner has stopped operating can lead to burns. Injuries may result. • Protective gloves must be worn. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. 238/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.1.1 Removing motor A1 Procedure 1. 2. 3. 4. Release and unplug connectors XM7 and XP7 at the sockets. Unscrew 4 M8x20-8.8-A2K Allen screws. Release and carefully lift out motor A1, taking care not to tilt it. Cover the aperture on motor mount A1 and protect it against fouling. Fig. 9-1: Motor A1 1 Motor A1 2 Connector XP7 3 Connector XM7 4 M8x20-8.8-A2K Allen screw 5. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.1.2 Installing motor A1 Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Check O-ring on motor shaft for damage and exchange if necessary. 3. Apply a thin but continuous coat of Microlube GL 261 grease to the toothing on the motor shaft. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 239/289 Repair KP1-H-2; KP1-HC-2 Repair KP1-H-2; KP1-HC-2 4. Position sockets XM7 and XP7 as shown in the illustration and insert the motor. Insertion of motor can be facilitated by turning it gently about its rotational axis. 5. Insert 4 M8x20-8.8-A2K Allen screws. 6. Tighten 4 M8x20-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 7. Plug connectors XM7 and XP7 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When inserting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-2: Motor A1 9.1.3 1 Motor A1 2 Connector XP7 3 Connector XM7 4 M8x20-8.8-A2K Allen screw Concluding work The following concluding work must be carried out: • Move A1 of the positioner and look out for irregularities. • Carry out mastering of A1. Detailed information about mastering is contained in the operating and programming instructions for end users or system integrators. 9.2 Exchanging motor A1; rated payload 1000 kg and 1500 kg Description The following sections describe the procedure for exchanging the motor on a positioner. 240/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Repair KP1-H-2; KP1-HC-2 Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Hexagon socket set - Torque wrench min. 20 Nm to 100 Nm - Torque wrench min. 2 Nm to 20 Nm - SEMD/MEMD mastering kit 0000-228-936 Material The following material is required: Designation Article number Quantity SPP motor 3.8kW L0 ME 1000-1500kg 0000-362-740 1 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The positioner controller must be switched off and secured to prevent unauthorized persons from switching it on again. • The power cable must be deenergized. • The positioner must be mechanically secured to prevent unintentional motions. • There is no fixture and no tool mounted on the positioner. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 241/289 Repair KP1-H-2; KP1-HC-2 Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. WARNING Danger to life and limb due to unintended positioner motions Unintended positioner motions may result in death, severe injuries and damage to property. • Secure the positioner by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. CAUTION Risk of burns on hot surfaces High motor surface temperatures immediately after the positioner has stopped operating can lead to burns. Injuries may result. • Protective gloves must be worn. WARNING Risk of crushing during removal and installation of motor When removing or installing the motor, there is a risk of injury by crushing. This could result in hand injuries. • Wear protective gloves. NOTICE Wear and premature failure due to damage to toothing Damage to the toothing of the motor and gear unit can lead to increased wear and premature failure of the components. • During cleaning, ensure that the toothing is not damaged. • Before installation, check the toothing of the motor and gear unit for damage. 9.2.1 Removing motor A1 Procedure 1. 2. 3. 4. 242/289 | www.kuka.com Release and unplug connectors XM7 and XP7 at the sockets. Unscrew 4 M12x30-8.8-A2K Allen screws. Release and carefully lift out motor A1, taking care not to tilt it. Cover the aperture on motor mount A1 and protect it against fouling. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Repair KP1-H-2; KP1-HC-2 Fig. 9-3: Motor A1 1 Motor A1 2 Connector XP7 3 Connector XM7 4 M12x30-8.8-A2K Allen screw 5. If the motor is not to be reinstalled, it must be disposed of properly or protected against corrosion before being put into storage. 9.2.2 Installing motor A1 Procedure 1. If a new motor is to be installed, remove any corrosion protection it may have prior to installation. 2. Check O-ring on motor shaft for damage and exchange if necessary. 3. Apply a thin but continuous coat of Microlube GL 261 grease to the toothing on the motor shaft. 4. Position sockets XM7 and XP7 as shown in the illustration and insert the motor. Insertion of motor can be facilitated by turning it gently about its rotational axis. 5. Insert 4 M12x30-8.8-A2K Allen screws. 6. Tighten 4 M12x30-8.8-A2K Allen screws with a torque wrench in diagonally opposite sequence. Increase the tightening torque to the specified value in several stages. 7. Plug connectors XM7 and XP7 into the sockets. The pins and coding elements of the connectors must be taken into consideration. When in- MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 243/289 KP1-H-2; KP1-HC-2 Repair serting the connectors, turn them until they clearly lock into the coding elements (twist-proof). Fig. 9-4: Motor A1 9.2.3 1 Motor A1 2 Connector XP7 3 Connector XM7 4 M12x30-8.8-A2K Allen screw Concluding work The following concluding work must be carried out: • Move A1 of the positioner and look out for irregularities. • Carry out mastering of A1. Detailed information about mastering is contained in the operating and programming instructions for end users or system integrators. 244/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 10 Decommissioning, storage and disposal 10.1 Decommissioning, KP1-H-2 Description This section describes all the work required for decommissioning the positioner if it is to be removed from the system. After decommissioning, it is prepared for storage or for transportation to a different location (>>> 6 "Transportation" Page 197). Equipment The following equipment is required: Designation Article number Lifting tackle / rope slings with sufficient load-bearing capacity - Crane with sufficient load-bearing capacity - 1 M12 swivel eyebolt - Angle grinder with metal cutting disc - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Precondition • The removal site is accessible for transportation with a crane. • There is no hazard posed by system components. Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. CAUTION Risk of injury due to sharp edges Sharp edges may occur when cutting open the weld seams. Injuries may result. • Suitable protective gloves must be worn. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 245/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 10.1.1 Releasing and disconnecting the connecting cables Procedure 1. Release and disconnect the peripheral connections. 2. Release and disconnect the motor cable and data cable connectors. Fig. 10-1: Connecting cables, example 10.1.2 1 Resolver cable XP7.1 2 Motor cable XM7.1 Removing the drive unit Procedure 1. Unscrew the M8 hexagon nut from the ground conductor, take off the washers and lock washers and pull off the ground conductor. 2. Release and unplug the connecting cables. 3. Screw 1 M12 swivel eyebolt into the pedestal at the top. 4. Pull the rope sling/lifting tackle through the swivel eyebolt and attach to the crane hook. 5. Carefully cut open all weld seams with a cut-off angle grinder. If necessary, use an angle grinder to deburr sharp edges (>>> Fig. 10-2). 6. Slacken 3 hexagon nuts (leveling screws) incl. 3 hexagon nuts and 3 thrust pins. 7. Lift the drive unit vertically off the mounting surface and transport it away. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. 246/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Fig. 10-2: Decommissioning 10.1.3 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) Concluding work The following concluding work must be carried out: • Prepare the positioner for storage if it is not to be reinstalled. 10.2 Decommissioning, KP1-HC-2 Description This section describes all the work required for decommissioning the positioner if it is to be removed from the system. After decommissioning, it is prepared for storage or for transportation to a different location (>>> 6 "Transportation" Page 197). Equipment The following equipment is required: Designation Article number Lifting tackle / rope slings with sufficient load-bearing capacity - Crane with sufficient load-bearing capacity - MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 247/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Designation Article number 2 M12 swivel eyebolts - Angle grinder with metal cutting disc - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Precondition • The removal site is accessible for transportation with a crane. • There is no hazard posed by system components. Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. CAUTION Risk of injury due to sharp edges Sharp edges may occur when cutting open the weld seams. Injuries may result. • Suitable protective gloves must be worn. 10.2.1 Releasing and disconnecting the connecting cables Procedure 1. Release and disconnect the peripheral connections. 2. Release and disconnect the motor cable and data cable connectors. 248/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Fig. 10-3: Connecting cables, example 10.2.2 1 Resolver cable XP7.1 2 Motor cable XM7.1 Removing the drive unit Procedure 1. Unscrew the M8 hexagon nut from the ground conductor, take off the washers and lock washers and pull off the ground conductor. 2. Release and unplug the connecting cables. 3. Screw 1 M12 swivel eyebolt into the pedestal at the top. 4. Pull the rope sling/lifting tackle through the swivel eyebolt and attach to the crane hook. 5. Carefully cut open all weld seams with a cut-off angle grinder. If necessary, use an angle grinder to deburr sharp edges (>>> Fig. 10-4). 6. Slacken 3 hexagon nuts (leveling screws) incl. 3 hexagon nuts and 3 thrust pins. 7. Lift the drive unit vertically off the mounting surface and transport it away. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 249/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Fig. 10-4: Decommissioning 10.2.3 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) Removing the counterbearing unit Procedure 1. Screw 1 M12 swivel eyebolt into the pedestal at the top. 2. Pull the rope sling/lifting tackle through the swivel eyebolt and attach to the crane hook. 3. Carefully cut open all weld seams with a cut-off angle grinder. If necessary, use an angle grinder to deburr sharp edges (>>> Fig. 10-5). 4. Slacken 3 hexagon nuts (leveling screws) incl. 3 hexagon nuts and 3 thrust pins. 5. Lift the counterbearing unit vertically off the mounting surface and transport it away. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. 250/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Fig. 10-5: Decommissioning 10.2.4 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) Concluding work The following concluding work must be carried out: • Prepare the positioner for storage if it is not to be reinstalled. 10.3 Storage, KP1-H-2 Description For storage, the positioner must be removed, cleaned and suitably covered. Storage location The storage location must meet the following requirements: • • • • • • • Virtually dry and free of dust Avoid temperature fluctuations Avoid wind and drafts Avoid condensation No exposure to direct sunlight Maintain the permissible temperature ranges for storage The packaging film cannot be damaged. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 251/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Equipment The following equipment is required: Designation Article number Lifting tackle / rope slings with sufficient load-bearing capacity - Crane with sufficient load-bearing capacity - 1 M12 swivel eyebolt - Angle grinder with metal cutting disc - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Permissible cleaning tools (e.g. cloths, brushes) - Material The following material is required: Designation Article number Quantity Covers that cannot detach themselves and which can withstand the expected environmental conditions - Cleaning agent solvent-free, water-soluble, non-flammable, non-aggressive, no steam, no refrigerants - - Precondition • Loose parts or parts that might knock against other parts have been removed from the positioner. • Tools and equipment have been removed. Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. 252/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 CAUTION Risk of injury due to sharp edges Sharp edges may occur when cutting open the weld seams. Injuries may result. • Suitable protective gloves must be worn. 10.3.1 Releasing and disconnecting the connecting cables Procedure 1. Release and disconnect the peripheral connections. 2. Release and disconnect the motor cable and data cable connectors. Fig. 10-6: Connecting cables, example 10.3.2 1 Resolver cable XP7.1 2 Motor cable XM7.1 Removing the drive unit Procedure 1. Unscrew the M8 hexagon nut from the ground conductor, take off the washers and lock washers and pull off the ground conductor. 2. Release and unplug the connecting cables. 3. Screw 1 M12 swivel eyebolt into the pedestal at the top. 4. Pull the rope sling/lifting tackle through the swivel eyebolt and attach to the crane hook. 5. Carefully cut open all weld seams with a cut-off angle grinder. If necessary, use an angle grinder to deburr sharp edges (>>> Fig. 10-7). 6. Slacken 3 hexagon nuts (leveling screws) incl. 3 hexagon nuts and 3 thrust pins. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 253/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 7. Lift the drive unit vertically off the mounting surface and transport it away. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. Fig. 10-7: Decommissioning 10.3.3 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) Cleaning Procedure 1. Shut down the positioner. 2. If necessary, shut adjacent system components down and lock them. 3. Remove enclosures if this is necessary in order to carry out the cleaning work. 4. Clean the positioner. 5. Fully remove all cleaning agents from the positioner. 6. Clean any areas of corrosion and reapply corrosion protection. 7. Install any safety equipment that has been removed. 8. Put back in place any enclosures that have been removed. 254/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 10.3.4 Preparing for storage Procedure 1. 2. 3. 4. Carry out a visual inspection of the positioner. Remove any foreign bodies. Remove any corrosion. Attach all covers to the positioner and check that the seals are correctly in place. 5. Seal off electrical connections with suitable covers. 6. Seal hose connections by suitable means. 7. Cover the positioner with plastic sheeting and seal it at the base frame against dust. If necessary, add a desiccant beneath the plastic sheeting. 10.3.5 Concluding work No concluding work is required. 10.4 Storage, KP1-HC-2 Description For storage, the positioner must be removed, cleaned and suitably covered. Storage location The storage location must meet the following requirements: • • • • • • • Virtually dry and free of dust Avoid temperature fluctuations Avoid wind and drafts Avoid condensation No exposure to direct sunlight Maintain the permissible temperature ranges for storage The packaging film cannot be damaged. Equipment The following equipment is required: Designation Article number Lifting tackle / rope slings with sufficient load-bearing capacity - Crane with sufficient load-bearing capacity - 2 M12 swivel eyebolts - Angle grinder with metal cutting disc - Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Permissible cleaning tools (e.g. cloths, brushes) - MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 255/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Material The following material is required: Designation Article number Quantity Covers that cannot detach themselves and which can withstand the expected environmental conditions - Cleaning agent solvent-free, water-soluble, non-flammable, non-aggressive, no steam, no refrigerants - - Precondition • Loose parts or parts that might knock against other parts have been removed from the positioner. • Tools and equipment have been removed. Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. CAUTION Risk of injury due to sharp edges Sharp edges may occur when cutting open the weld seams. Injuries may result. • Suitable protective gloves must be worn. 10.4.1 Releasing and disconnecting the connecting cables Procedure 1. Release and disconnect the peripheral connections. 2. Release and disconnect the motor cable and data cable connectors. 256/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Fig. 10-8: Connecting cables, example 10.4.2 1 Resolver cable XP7.1 2 Motor cable XM7.1 Removing the drive unit Procedure 1. Unscrew the M8 hexagon nut from the ground conductor, take off the washers and lock washers and pull off the ground conductor. 2. Release and unplug the connecting cables. 3. Screw 1 M12 swivel eyebolt into the pedestal at the top. 4. Pull the rope sling/lifting tackle through the swivel eyebolt and attach to the crane hook. 5. Carefully cut open all weld seams with a cut-off angle grinder. If necessary, use an angle grinder to deburr sharp edges (>>> Fig. 10-9). 6. Slacken 3 hexagon nuts (leveling screws) incl. 3 hexagon nuts and 3 thrust pins. 7. Lift the drive unit vertically off the mounting surface and transport it away. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 257/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Fig. 10-9: Decommissioning 10.4.3 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) Removing the counterbearing unit Procedure 1. Screw 1 M12 swivel eyebolt into the pedestal at the top. 2. Pull the rope sling/lifting tackle through the swivel eyebolt and attach to the crane hook. 3. Carefully cut open all weld seams with a cut-off angle grinder. If necessary, use an angle grinder to deburr sharp edges (>>> Fig. 10-10). 4. Slacken 3 hexagon nuts (leveling screws) incl. 3 hexagon nuts and 3 thrust pins. 5. Lift the counterbearing unit vertically off the mounting surface and transport it away. WARNING If the positioner is caught on the mounting surface, it may come free abruptly, endangering persons and property. The positioner must stand loosely on the mounting surface; completely remove all fastening materials and any adhesives. 258/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 Fig. 10-10: Decommissioning 10.4.4 1 Booster frame 2 Bedplate 3 Welding strip (6x) 4 M12x100-8.8-A2K hexagon bolt (3x) 5 Thrust pin (3x) 6 M24 hexagon nut, type 1 (3x) Cleaning Procedure 1. Shut down the positioner. 2. If necessary, shut adjacent system components down and lock them. 3. Remove enclosures if this is necessary in order to carry out the cleaning work. 4. Clean the positioner. 5. Fully remove all cleaning agents from the positioner. 6. Clean any areas of corrosion and reapply corrosion protection. 7. Install any safety equipment that has been removed. 8. Put back in place any enclosures that have been removed. 10.4.5 Preparing for storage Procedure 1. Carry out a visual inspection of the positioner. 2. Remove any foreign bodies. 3. Remove any corrosion. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 259/289 Decommissioning, storage and disposal KP1-H-2; KP1-HC-2 4. Attach all covers to the positioner and check that the seals are correctly in place. 5. Seal off electrical connections with suitable covers. 6. Seal hose connections by suitable means. 7. Cover the positioner with plastic sheeting and seal it at the base frame against dust. If necessary, add a desiccant beneath the plastic sheeting. 10.4.6 Concluding work No concluding work is required. 10.5 Disposal Description When the positioner reaches the end of its useful life, it can be removed from the system and dismantled, and the materials can be disposed of properly by type. The following table provides an overview of the materials used in the positioner. All plastic components are marked with a material designation and must be disposed of accordingly. Material Subassembly, component Additional information Metals Copper Cables, wires Steel Covers, booster frame, pedestals, gear units, screws and washers Electrical parts Motors Dispose of motors without dismantling. Plastics EPDM Seals, covers NBR O-rings, shaft seals PTFE Sealing rings PUR Cable sheaths Auxiliary substances and consumables Gear oil Gear units Optigear Synt. ALR 150 Up-to-date safety data sheets must be requested from the manufacturers of auxiliary and operating materials. Further information about the auxiliary substances and consumables used can be found under: (>>> 12.2 "Auxiliary and operating materials used" Page 282). 260/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options KP1-H-2; KP1-HC-2 11 Options 11.1 Current collector (optional) Description The current collector is an option for the positioner. It is used to carry out ground return during welding via a sliding contact. The energy generated during the weld process is picked up and discharged via the weld current return. The energy is transferred by means of the grounding cables (not included in the scope of supply). Using the weld current return option allows the respective axis to be designed as an infinitely rotating axis. The current collector consists of the following components: • • • • • • Contact surface of plunger holder Plunger holder with integrated compression spring Connection plate Holder Insulating plate Fastening materials Fig. 11-1: Current collector, example 1 Contact surface of plunger holder 2 Plunger holder with integrated compression spring 3 Connection plate 4 Holder 5 Insulating plate Basic data Article number Current collector, drive 0000-355-920 Weight Current collector, drive approx. 3 kg Article number Current collector, counterbearing 0000-380-922 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 261/289 Options KP1-H-2; KP1-HC-2 Weight Current collector, counterbearing approx. 3 kg Current rating under continuous load max. 500 A Further information about the ambient conditions is contained in the assembly instructions for the robot and robot controller. Dimensions The following diagram shows the dimensions of the current collector for: Fig. 11-2: Dimensions, current collector Planning The following points must be observed when planning and routing the grounding cable: • Protect cables against exposure to mechanical stress. • Route the cables without mechanical stress – no tensile forces on the connectors. • Observe the permissible temperature range (fixed installation) of 263 K (-10 °C) to 343 K (+55 °C). Transportation The components must be suitably and properly packaged prior to transportation. The components must be protected against damage with shockresistant and break-proof packaging. The following measures are to be taken before assemblies and individual components are transported: • Clean components. • Assign small parts to their respective components in plastic bags to prevent them from getting lost. • Protect components against impacts and slipping; fill gaps with suitable approved padding materials. Mark transport cases and packing according to the sensitivity of their contents (e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure correct transportation (e.g. indication of center of gravity). In addition to 262/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 these measures, the regulations and conditions of the company entrusted with the transportation are to be observed. Start-up and recommissioning • Drive unit: (>>> 11.1.1 "Putting current collector into operation, drive unit" Page 264) • Counterbearing unit: (>>> 11.1.2 "Putting current collector into operation, counterbearing unit" Page 267) Maintenance Fig. 11-3: Maintenance chart, current collector, example Interval Item Activity 6 months 1 Check tightening torques for screws. 6 months 2 Visual inspection: Check the contact surfaces of the plunger holder. • The contact surface must be smooth and even. • The recesses on the contact surface must be visible. • If unevenness is detected, the current collector must be exchanged. (>>> 11.1.3 "Exchanging the current collector, drive unit" Page 271) 6 months 3 Check that compression spring moves freely. (Compression spring is not visible from outside.) • Compression spring must move freely. • If it does not move freely, the current collector must be exchanged. (>>> 11.1.3 "Exchanging the current collector, drive unit" Page 271) Repair (>>> 11.1.3 "Exchanging the current collector, drive unit" Page 271) Disposal When the cover reaches the end of its useful life, it can be removed and disposed of. The materials must be disposed of in accordance with the pertinent regulations or recycled. The following table provides an overview of the materials used. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 263/289 Options KP1-H-2; KP1-HC-2 Options KP1-H-2; KP1-HC-2 Material Subassembly, component Additional information Metals Steel Connection plate, screws, washers, holders Plunger holder Dispose of plunger holder without dismantling. Insulating plate - Plastics HGW2082 11.1.1 Putting current collector into operation, drive unit Description The following instructions describe the procedure for installing the current collector on a positioner. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 Nm to 100 Nm - Material The following material is required: Designation Article number Quantity WGR endless rotating H/MD 01 DS 0000-355-920 1 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The positioner controller must be switched off and secured to prevent unauthorized persons from switching it on again. • The power cable must be deenergized. • The positioner must be mechanically secured to prevent unintentional motions. • There is no fixture and no tool mounted on the positioner. 264/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options KP1-H-2; KP1-HC-2 Work safety WARNING Danger to life and limb due to unintended positioner motions Unintended positioner motions may result in death, severe injuries and damage to property. • Secure the positioner by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 11.1.1.1 Removing the cover on the drive side Procedure 1. Unscrew 3 M6x10-A2-70 round head Allen screws (flat version) from the cover. 2. Remove the cover from the housing. Fig. 11-4: Cover on the drive side, example 11.1.1.2 1 Housing 2 Cover on drive side 3 M6x10-A2-70 round head Allen screw (flat version) Installing the current collector Procedure 1. Position the current collector in the housing and fasten with 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 insulating bushings. Ensure that the installation position is correct. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 265/289 Options KP1-H-2; KP1-HC-2 Fig. 11-5: Current collector 1 Copper bar 2 M8x25-8.8-A2K Allen screw with washer and insulating bushing 2. Place the customer-specific cable (not included in the scope of supply) on the copper bar and fasten it with the cable gland. Fig. 11-6: Grounding cable, example 11.1.1.3 1 Copper bar 2 Cable gland 3 Grounding cable Installing the cover on the drive side Procedure 1. Place cover on housing, align and fasten with 3 M6x10-A2-70 round head Allen screws (flat version). 266/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options KP1-H-2; KP1-HC-2 Fig. 11-7: Cover on the drive side, example 11.1.1.4 1 Housing 2 Cover on drive side 3 M6x10-A2-70 round head Allen screw (flat version) Concluding work The following concluding work must be carried out: • Carry out a test run in T1 mode and look out for irregularities. 11.1.2 Putting current collector into operation, counterbearing unit Description The following instructions describe the procedure for installing the current collector on a positioner. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 Nm to 100 Nm - Material The following material is required: Designation Article number Quantity WGR endless rotating HC/MC 01 CB 0000-380-922 1 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 267/289 Options KP1-H-2; KP1-HC-2 Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The positioner must be mechanically secured to prevent unintentional motions. • There is no fixture and no tool mounted on the positioner. Valid for product family KP1-MDC-2: • The positioner controller must be switched off and secured to prevent unauthorized persons from switching it on again. • The power cable must be deenergized. Work safety Valid for product family KP1-MDC-2: WARNING Danger to life and limb due to unintended positioner motions Unintended positioner motions may result in death, severe injuries and damage to property. • Secure the positioner by pressing the EMERGENCY STOP device. • Warn all persons concerned before starting to put it back into operation. 11.1.2.1 Removing the cover from the counterbearing Procedure 1. Unscrew 3 M6x10-A2-70 round head Allen screws (flat version) from the cover. 2. Remove the cover from the counterbearing. 268/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options KP1-H-2; KP1-HC-2 Fig. 11-8: Cover on counterbearing 11.1.2.2 1 Counterbearing 2 Cover 3 M6x10-A2-70 round head Allen screw (flat version) Installing the current collector Procedure 1. Position the current collector in the housing and fasten with 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 insulating bushings. Ensure that the installation position is correct. Fig. 11-9: Current collector 1 Copper bar 2 M8x25-8.8-A2K Allen screw with washer and insulating bushing 2. Place the customer-specific cable (not included in the scope of supply) on the copper bar and fasten it with the cable gland. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 269/289 Options KP1-H-2; KP1-HC-2 Fig. 11-10: Grounding cable, example 11.1.2.3 1 Copper bar 2 Cable gland 3 Grounding cable Installing the cover on the counterbearing Procedure 1. Mount the cover on the counterbearing and fasten it with 3 M6x10A2-70 round head Allen screws (flat version). Fig. 11-11: Cover on counterbearing 270/289 | www.kuka.com 1 Counterbearing 2 Cover 3 M6x10-A2-70 round head Allen screw (flat version) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 Concluding work Options 11.1.2.4 The following concluding work must be carried out: • Carry out a test run in T1 mode and look out for irregularities. 11.1.3 Exchanging the current collector, drive unit Description The following sections describe the procedure for exchanging the current collector on a positioner. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 Nm to 100 Nm - Torque wrench min. 2 Nm to 20 Nm - Material The following material is required: Designation Article number Quantity WGR endless rotating H/MD 01 DS 0000-355-920 1 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The positioner controller must be switched off and secured to prevent unauthorized persons from switching it on again. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 271/289 Options KP1-H-2; KP1-HC-2 • The power cable must be deenergized. • The positioner must be mechanically secured to prevent unintentional motions. • There is no fixture and no tool mounted on the positioner. Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. 11.1.3.1 Removing the cover on the drive side Procedure 1. Unscrew 3 M6x10-A2-70 round head Allen screws (flat version) from the cover. 2. Remove the cover from the housing. Fig. 11-12: Cover on the drive side, example 272/289 | www.kuka.com 1 Housing 2 Cover on drive side 3 M6x10-A2-70 round head Allen screw (flat version) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 Removing the current collector Options 11.1.3.2 Procedure 1. Disconnect and remove the grounding cable from the copper bar. Grounding cable is possibly not included in the scope of supply; customer-specific. Fig. 11-13: Grounding cable, example 1 Copper bar 2 Cable gland 3 Grounding cable 2. Unscrew 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 insulating bushings from the current collector. 3. Take the current collector carefully out of the housing. Fig. 11-14: Current collector 11.1.3.3 1 Copper bar 2 M8x25-8.8-A2K Allen screw with washer and insulating bushing Installing the current collector Procedure 1. Position the current collector in the housing and fasten with 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 insulating bushings. Ensure that the installation position is correct. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 273/289 Options KP1-H-2; KP1-HC-2 Fig. 11-15: Current collector 1 Copper bar 2 M8x25-8.8-A2K Allen screw with washer and insulating bushing 2. Place the customer-specific cable (not included in the scope of supply) on the copper bar and fasten it with the cable gland. Fig. 11-16: Grounding cable, example 11.1.3.4 1 Copper bar 2 Cable gland 3 Grounding cable Installing the cover on the drive side Procedure 1. Place cover on housing, align and fasten with 3 M6x10-A2-70 round head Allen screws (flat version). 274/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options KP1-H-2; KP1-HC-2 Fig. 11-17: Cover on the drive side, example 11.1.3.5 1 Housing 2 Cover on drive side 3 M6x10-A2-70 round head Allen screw (flat version) Concluding work The following concluding work must be carried out: • Move the positioner and look out for irregularities. • Run the program in T1 mode and look out for irregularities. • Carry out a function test. 11.1.4 Exchanging the current collector, counterbearing unit Description The following sections describe the procedure for exchanging the current collector on a positioner. Equipment The following equipment is required: Designation Article number Set of Allen keys 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm - Torque wrench min. 20 Nm to 100 Nm - Torque wrench min. 2 Nm to 20 Nm - MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 275/289 Options KP1-H-2; KP1-HC-2 Material The following material is required: Designation Article number Quantity WGR endless rotating HC/MC 01 CB 0000-380-922 1 Procurement of spare parts Defective components must only be replaced with original spare parts from KUKA Deutschland GmbH. Non-compliance nullifies warranty and liability claims. A “Repair Card” is supplied with the exchange parts. This must be completed and returned to KUKA Deutschland GmbH together with the defective component in the following cases. • Within the warranty period • If, after consultation with KUKA Deutschland GmbH, an examination of the defective component by KUKA is required. Tightening torques The tightening torques can be found under: (>>> 12.1 "Tightening torques" Page 281) These are valid for screws and nuts where no other specifications are given. Screws of strength class 10.9 and higher as well as screws with test certification may only be tightened once with the rated tightening torque. When the screws are first slackened they must be replaced with new ones. Precondition • The positioner controller must be switched off and secured to prevent unauthorized persons from switching it on again. • The power cable must be deenergized. • The positioner must be mechanically secured to prevent unintentional motions. • There is no fixture and no tool mounted on the positioner. Work safety WARNING Danger to life and limb due to live components Components may remain energized after the positioner has been switched off. Death, severe injuries or damage to property may result. • Switch off the positioner at the main switch and secure it to prevent unauthorized persons from switching it on again. • Disconnect the power cable from the supply. • After switching off, wait at least 5 minutes and then check to ensure that the controller and power cable are deenergized. 11.1.4.1 Removing the cover from the counterbearing Procedure 1. Unscrew 3 M6x10-A2-70 round head Allen screws (flat version) from the cover. 2. Remove the cover from the counterbearing. 276/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options KP1-H-2; KP1-HC-2 Fig. 11-18: Cover on counterbearing 11.1.4.2 1 Counterbearing 2 Cover 3 M6x10-A2-70 round head Allen screw (flat version) Removing the current collector Procedure 1. Disconnect and remove the grounding cable from the copper bar. Grounding cable is possibly not included in the scope of supply; customer-specific. Fig. 11-19: Grounding cable, example 1 Copper bar 2 Cable gland MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 277/289 Options KP1-H-2; KP1-HC-2 3 Grounding cable 2. Unscrew 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 insulating bushings from the current collector. 3. Take the current collector carefully out of the housing. Fig. 11-20: Current collector 11.1.4.3 1 Copper bar 2 M8x25-8.8-A2K Allen screw with washer and insulating bushing Installing the current collector Procedure 1. Position the current collector in the housing and fasten with 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 insulating bushings. Ensure that the installation position is correct. Fig. 11-21: Current collector 1 Copper bar 2 M8x25-8.8-A2K Allen screw with washer and insulating bushing 2. Place the customer-specific cable (not included in the scope of supply) on the copper bar and fasten it with the cable gland. 278/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Options KP1-H-2; KP1-HC-2 Fig. 11-22: Grounding cable, example 11.1.4.4 1 Copper bar 2 Cable gland 3 Grounding cable Installing the cover on the counterbearing Procedure 1. Mount the cover on the counterbearing and fasten it with 3 M6x10A2-70 round head Allen screws (flat version). Fig. 11-23: Cover on counterbearing 1 Counterbearing 2 Cover 3 M6x10-A2-70 round head Allen screw (flat version) MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 279/289 Options KP1-H-2; KP1-HC-2 11.1.4.5 Concluding work The following concluding work must be carried out: • Move the positioner and look out for irregularities. • Run the program in T1 mode and look out for irregularities. • Carry out a function test. 280/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 12 Appendix 12.1 Tightening torques Appendix KP1-H-2; KP1-HC-2 Tightening torques The following tightening torques (Nm) are valid for screws and nuts where no other specifications are given. The specified values apply to lightly oiled black (e.g. phosphated) and coated (e.g. mech. galv., zinc flake plating, screw locking elements) screws and nuts. Strength class Thread 8.8 10.9 12.9 M1.6 0.17 Nm 0.24 Nm 0.28 Nm M2 0.35 Nm 0.48 Nm 0.56 Nm M2.5 0.68 Nm 0.93 Nm 1.10 Nm M3 1.2 Nm 1.6 Nm 2.0 Nm M4 2.8 Nm 3.8 Nm 4.4 Nm M5 5.6 Nm 7.5 Nm 9.0 Nm M6 9.5 Nm 12.5 Nm 15.0 Nm M8 23.0 Nm 31.0 Nm 36.0 Nm M10 45.0 Nm 60.0 Nm 70.0 Nm M12 78.0 Nm 104.0 Nm 125.0 Nm M14 125.0 Nm 165.0 Nm 195.0 Nm M16 195.0 Nm 250.0 Nm 305.0 Nm M20 370.0 Nm 500.0 Nm 600.0 Nm M24 640.0 Nm 860.0 Nm 1030.0 Nm M30 1330.0 Nm 1700.0 Nm 2000.0 Nm Strength class Thread 8.8 ISO7991 Allen screw 10.9 ISO7380, ISO07381 Fillister head screw M3 0.8 Nm 0.8 Nm M4 1.9 Nm 1.9 Nm M5 3.8 Nm 3.8 Nm Strength class Thread 10.9 DIN7984 Pan head screws M4 2.8 Nm Tighten M5 domed cap nuts with a torque of 4.2 Nm. MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 281/289 Appendix KP1-H-2; KP1-HC-2 12.2 Auxiliary and operating materials used Product designation / Article number Use Manufacturer designation / Address Optigear Synt. ALR 150_EEA Gear oil BP Europa SE Geschäftsbereich Industrieschmierstoffe Erkelenzer Strasse 20 D-41179 Mönchengladbach Germany Lubricating grease Deutsche BP Aktiengesellschaft - Industrial Lubricants & Services Erkelenzer Strasse 20 D-41179 Mönchengladbach Germany 0000-362-835 for European Economic Area Optigear Synt. ALR 150_AM1 0000-361-461 for USA, Canada, Mexico, Chile, Peru Optigear Synt. ALR 150_CHN 0000-361-473 for China Optigear Synt. ALR 150_APeC1 0000-361-476 for India, Taiwan, Japan, Thailand, South Korea, Malaysia Article numbers for further regions can be found in KUKA Xpert. Optitemp RB 2 0000-101-456 To ensure safe use of our products, we recommend regularly requesting up-to-date safety data sheets from the manufacturers of auxiliary and operating materials. 12.3 Weld seams - Quality requirements Welding personnel Only suitably qualified personnel may carry out welding work. Welding When carrying out welding work on the positioner, the standards listed in the following table must be observed: Quality requirement ISO 3834-2 ISO 3834-3 ISO 3834-4 282/289 | www.kuka.com Weld seam preparation ISO 9692-1 Weld seams EN 22553 Welding process ISO 4063-135 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Quality level ISO 5817-B (St) ISO 5817-C (St) ISO 10042-C (Al) Tolerance class ISO 13920-BF ISO 13920-CG 12.4 Dye penetrant inspection Not required Magnetic particle testing Not required Ultrasonic testing Not required Radiographic testing Not required Weld spatter Remove Temper colors Remove on stainless steel Applied standards and regulations Name/Edition Definition 2006/42/EC Machinery Directive: Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast) 2014/30/EU EMC Directive: Directive 2014/30/EU of the European Parliament and of the Council dated 26 February 2014 on the approximation of the laws of the Member States concerning electromagnetic compatibility EN 614-1:2006+A1:2009 Safety of machinery: Ergonomic design principles - Part 1: Terms and general principles EN 60204-1:2018 Safety of machinery: Electrical equipment of machines – Part 1: General requirements EN 61000-6-2:2005 Electromagnetic compatibility (EMC): Part 6-2: Generic standards; Immunity for industrial environments EN 61000-6-4:2007 + A1:2011 EN ISO 10218-1:2011 Electromagnetic compatibility (EMC): Part 6-4: Generic standards; Emission standard for industrial environments Robots and robotic devices – Safety requirements for industrial robots: Part 1: Robots Note: Content equivalent to ANSI/RIA R15.06-2012, Part 1 EN ISO 12100:2010 Safety of machinery: General principles of design, risk assessment and risk reduction EN ISO 13849-1:2015 Safety of machinery: Safety-related parts of control systems - Part 1: General principles of design MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 283/289 Appendix KP1-H-2; KP1-HC-2 Appendix KP1-H-2; KP1-HC-2 EN ISO 13849-2:2012 Safety of machinery: Safety-related parts of control systems - Part 2: Validation EN ISO 13850:2015 Safety of machinery: Emergency stop - Principles for design 284/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 13 KUKA Service 13.1 Requesting support KUKA Service KP1-H-2; KP1-HC-2 Introduction This documentation provides information on operation and operator control, and provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary. Information The following information is required for processing a support request: • Description of the problem, including information about the duration and frequency of the fault • The greatest possible amount of information about the hardware and software components of the overall system The following list gives an indication of the information which is relevant in many cases: ‒ Model and serial number of the kinematic system, e.g. the manipulator ‒ Model and serial number of the controller ‒ Model and serial number of the energy supply system ‒ Designation and version of the system software ‒ Designations and versions of other software components or modifications ‒ System Software diagnosis package Additionally for KUKA Sunrise: Existing projects including applications For versions of KUKA System Software older than V8: Archive of the software (Diagnosis package is not yet available here.) ‒ Application used ‒ External axes used 13.2 KUKA Customer Support The contact details of the local subsidiaries can be found at: www.kuka.com/customer-service-contacts MA KP1-H-HC-2 V2 | Issued: 10.10.2022 www.kuka.com | 285/289 KUKA Service KP1-H-2; KP1-HC-2 286/289 | www.kuka.com MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 Index 2006/42/EC................................................... 283 2014/30/EU................................................... 283 95/16/EC....................................................... 283 A Accessories.............................................. 14, 17 ANSI/RIA R15.06-2012................................ 283 Appendix....................................................... 281 Automatic mode..............................................28 Auxiliary materials used............................... 282 Axis data, .. 38, 44, 50, 56, 62, 68, 74, 80, 86, 92, 98, 104, 110, 116, 122, 128, 134, 140, 146, 152, 158, 164, 170, 176 Axis limitation, mechanical............................. 22 Axis range................................................ 10, 18 B Basic data, KP1-H1000 R1000-2.................. 78 Basic data, KP1-H1000 R1200-2.................. 84 Basic data, KP1-H1000 R800-2.................... 72 Basic data, KP1-H1500 R1000-2.................. 96 Basic data, KP1-H1500 R1200-2................ 102 Basic data, KP1-H1500 R800-2.................... 90 Basic data, KP1-H500 R1000-2.................... 42 Basic data, KP1-H500 R1200-2.................... 48 Basic data, KP1-H500 R800-2...................... 36 Basic data, KP1-H750 R1000-2.................... 60 Basic data, KP1-H750 R1200-2.................... 66 Basic data, KP1-H750 R800-2...................... 54 Basic data, KP1-HC1000 R1000-2..............150 Basic data, KP1-HC1000 R1200-2..............156 Basic data, KP1-HC1000 R800-2................144 Basic data, KP1-HC1500 R1000-2..............168 Basic data, KP1-HC1500 R1200-2..............174 Basic data, KP1-HC1500 R800-2................162 Basic data, KP1-HC500 R1000-2................ 114 Basic data, KP1-HC500 R1200-2................120 Basic data, KP1-HC500 R800-2..................108 Basic data, KP1-HC750 R1000-2................132 Basic data, KP1-HC750 R1200-2................138 Basic data, KP1-HC750 R800-2..................126 Booster frame................................................. 14 Brake defect................................................... 24 Brake release device......................................23 Braking distance.......................................10, 18 C CE mark..........................................................18 Center of gravity.................................. 197, 199 Cleaning work.................................................29 Concluding work...................................212, 221 Connecting cable, standard......................... 229 Connecting cables................................. 17, 194 Connecting cables, KR C4.. 37, 43, 49, 55, 61, 67, 73, 79, 85, 91, 97, 103, 109, 115, 121, MA KP1-H-HC-2 V2 | Issued: 10.10.2022 127, 133, 139, 145, 151, 157, 163, 169, 175, 222 Connecting cables, KR C5.. 38, 44, 50, 56, 62, 68, 74, 80, 86, 92, 98, 104, 110, 116, 122, 128, 134, 140, 146, 152, 158, 164, 170, 176, 228 Counterbalancing system............................... 30 Counterbearing unit...................................... 188 Current collector (optional)...........................261 Current collector, counterbearing unit, exchanging................................................... 275 Current collector, counterbearing unit, putting into operation................................................267 Current collector, drive unit, exchanging..... 271 Current collector, drive unit, putting into operation.......................................................264 Current collector, removing..................273, 277 D Danger zone.............................................10, 19 Declaration of conformity............................... 18 Declaration of incorporation.....................17, 18 Decommissioning................................... 31, 245 Decommissioning, KP1-H-2......................... 245 Decommissioning, KP1-HC-2.......................247 Description, positioner.................................... 13 Diagnosis package....................................... 285 Dimensions, transport.......................... 197, 199 Directives...................................................... 283 Disclaimer....................................................... 17 Disposal......................................... 31, 245, 260 Documentation, positioning system................. 9 Drive pedestal.................................................14 Drive unit................................................ 10, 186 E EC declaration of conformity......................... 18 Electrical installations..................................... 14 Electromagnetic compatibility (EMC)........... 283 Electromagnetic compatibility (EMC):.......... 283 EMC Directive........................................ 18, 283 EMD................................................................ 10 EMT................................................................ 10 EN 60204-1:2018......................................... 283 EN 61000-6-2:2005...................................... 283 EN 61000-6-4:2007 + A1:2011.................... 283 EN 614-1:2006+A1:2009..............................283 EN ISO 10218-1:2011.................................. 283 EN ISO 12100:2010..................................... 283 EN ISO 13849-1:2015..................................283 EN ISO 13849-2:2012..................................284 EN ISO 13850:2015..................................... 284 Energy supply system.................................... 13 External axes..................................................17 External axis.............................................11, 20 F www.kuka.com | 287/289 KP1-H-2; KP1-HC-2 Face plates, dimensions.............................. 190 Faults.............................................................. 25 Foundation loads, KP1-H1000 R1000-2........83 Foundation loads, KP1-H1000 R1200-2........89 Foundation loads, KP1-H1000 R800-2..........77 Foundation loads, KP1-H1500 R1000-2......101 Foundation loads, KP1-H1500 R1200-2......107 Foundation loads, KP1-H1500 R800-2..........95 Foundation loads, KP1-H500 R1000-2..........47 Foundation loads, KP1-H500 R1200-2..........53 Foundation loads, KP1-H500 R800-2............41 Foundation loads, KP1-H750 R1000-2..........65 Foundation loads, KP1-H750 R1200-2..........71 Foundation loads, KP1-H750 R800-2............59 Foundation loads, KP1-HC1000 R1000-2... 155 Foundation loads, KP1-HC1000 R1200-2... 161 Foundation loads, KP1-HC1000 R800-2..... 149 Foundation loads, KP1-HC1500 R1000-2... 173 Foundation loads, KP1-HC1500 R1200-2... 179 Foundation loads, KP1-HC1500 R800-2..... 167 Foundation loads, KP1-HC500 R1000-2..... 119 Foundation loads, KP1-HC500 R1200-2..... 125 Foundation loads, KP1-HC500 R800-2....... 113 Foundation loads, KP1-HC750 R1000-2..... 137 Foundation loads, KP1-HC750 R1200-2..... 143 Foundation loads, KP1-HC750 R800-2....... 131 Function test................................................... 26 Linear unit.......................................................17 Low Voltage Directive.....................................18 G O General safety measures............................... 23 Ground conductor................................ 228, 232 H Handling equipment.....................197, 206, 215 Hazardous substances................................... 30 I Industrial robot................................................17 Interface, connecting cables................222, 228 Interfaces...................................................... 194 Introduction....................................................... 9 K KCP....................................................10, 19, 24 Keyboard, external......................................... 25 KP................................................................... 10 KR C............................................................... 10 KUKA Customer Support............................. 285 KUKA Service...............................................285 KUKA smartPAD...................................... 10, 19 KUKA smartPAD-2................................... 10, 19 L Labeling.......................................................... 23 288/289 | www.kuka.com M Machine data........................................209, 219 Machinery Directive................................18, 283 Maintenance........................................... 29, 233 Maintenance overview..................................233 Maintenance symbols...................................234 Maintenance table........................................ 234 Manipulator.........................................11, 17, 19 Manual mode..................................................27 Material designation..................................... 260 Mechanical end stops.................................... 22 Misuse.............................................................16 Motor A1, exchanging; rated payload 1000 kg.........................................................240 Motor A1, exchanging; rated payload 1500 kg.........................................................240 Motor A1, exchanging; rated payload 500 kg...........................................................237 Motor A1, exchanging; rated payload 750 kg...........................................................237 Mounting base.............................................. 183 Mounting base, installing..................... 206, 215 Mouse, external.............................................. 25 Oil temperatures........................................... 233 Operating materials used............................. 282 Operators........................................................ 21 Optigear Synt. ALR 150...............................282 Options.............................................15, 17, 261 Optitemp RB 2..............................................282 Overload......................................................... 24 Overview, positioner....................................... 13 P Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, Payloads, KP1-H1000 R1000-2..................... 82 KP1-H1000 R1200-2..................... 88 KP1-H1000 R800-2....................... 76 KP1-H1500 R1000-2................... 100 KP1-H1500 R1200-2................... 106 KP1-H1500 R800-2....................... 94 KP1-H500 R1000-2....................... 46 KP1-H500 R1200-2....................... 52 KP1-H500 R800-2......................... 40 KP1-H750 R1000-2....................... 64 KP1-H750 R1200-2....................... 70 KP1-H750 R800-2......................... 58 KP1-HC1000 R1000-2................ 154 KP1-HC1000 R1200-2................ 160 KP1-HC1000 R800-2.................. 148 KP1-HC1500 R1000-2................ 172 KP1-HC1500 R1200-2................ 178 KP1-HC1500 R800-2.................. 166 KP1-HC500 R1000-2...................118 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 KP1-H-2; KP1-HC-2 Payloads, KP1-HC500 R1200-2.................. 124 Payloads, KP1-HC500 R800-2.....................112 Payloads, KP1-HC750 R1000-2.................. 136 Payloads, KP1-HC750 R1200-2.................. 142 Payloads, KP1-HC750 R800-2.................... 130 Personal protective equipment...................... 20 Personnel........................................................20 Planning........................................................ 183 Plant integrator............................................... 20 Plates and labels..........................................180 Positioner........................................................ 17 Positioner, cleaning...................................... 235 Positioner, installing............................. 207, 216 PPE.................................................................20 Preparing for storage...........................255, 259 Pressure Equipment Directive........................30 Preventive maintenance work........................ 29 Product description.........................................13 Protective equipment, overview..................... 21 R RDC................................................................ 11 Reaction distance.....................................10, 18 Recommissioning................................... 26, 203 Regulations................................................... 283 Release device............................................... 22 Repair..................................................... 29, 237 Robot controller.............................................. 17 S Safety..............................................................17 Safety instructions............................................ 9 Safety of machinery.............................283, 284 Safety options.................................................19 Safety zone........................................ 11, 19, 21 Safety, general................................................17 Service life...................................................... 19 smartPAD........................................... 11, 19, 24 Software..........................................................17 Spare parts..........................237, 241, 271, 276 Standards......................................................283 Start-up...................................................26, 203 Start-up, positioner (mounting base)........... 203 Start-up, positioner KP1-HC-2 (mounting base).............................................................212 STOP 0............................................ 11, 19, 182 STOP 1.....................................................11, 19 STOP 2.....................................................11, 20 Stop category 0........................................11, 19 Stop category 1........................................11, 19 Stop category 2........................................11, 20 Stop category 1, Drive Ramp Stop............... 20 STOP 1 - DRS............................................... 20 Stopping distance.................................... 10, 18 Stopping distances....................................... 182 Storage................................................... 31, 245 Storage, KP1-H-2......................................... 251 Storage, KP1-HC-2.......................................255 MA KP1-H-HC-2 V2 | Issued: 10.10.2022 Support request............................................ 285 System integrator.............................. 18, 20, 21 T T1 (operating mode)................................ 11, 20 T2 (operating mode)................................ 11, 20 Teach pendant................................................ 17 Technical data.................................................33 Technical data, KP1-H1000 R1000-2............ 78 Technical data, KP1-H1000 R1200-2............ 84 Technical data, KP1-H1000 R800-2.............. 72 Technical data, KP1-H1500 R1000-2............ 96 Technical data, KP1-H1500 R1200-2.......... 102 Technical data, KP1-H1500 R800-2.............. 90 Technical data, KP1-H500 R1000-2.............. 42 Technical data, KP1-H500 R1200-2.............. 48 Technical data, KP1-H500 R800-2................ 36 Technical data, KP1-H750 R1000-2.............. 60 Technical data, KP1-H750 R1200-2.............. 66 Technical data, KP1-H750 R800-2................ 54 Technical data, KP1-HC1000 R1000-2........150 Technical data, KP1-HC1000 R1200-2........156 Technical data, KP1-HC1000 R800-2..........144 Technical data, KP1-HC1500 R1000-2........168 Technical data, KP1-HC1500 R1200-2........174 Technical data, KP1-HC1500 R800-2..........162 Technical data, KP1-HC500 R1000-2.......... 114 Technical data, KP1-HC500 R1200-2..........120 Technical data, KP1-HC500 R800-2............108 Technical data, KP1-HC750 R1000-2..........132 Technical data, KP1-HC750 R1200-2..........138 Technical data, KP1-HC750 R800-2............126 Technical data, overview................................ 33 Terms used..................................................... 10 Terms, safety.................................................. 18 Tightening torques........................................ 281 Training............................................ 9, 233, 237 Transport, drive unit..................................... 197 Transportation........................................ 25, 197 Transportation, counterbearing unit............. 199 Transportation, overview.............................. 197 Turn-tilt table...................................................17 U Use Intended..................................................... 16 User.......................................................... 18, 20 W Warnings........................................................... 9 Workspace......................................... 10, 18, 21 www.kuka.com | 289/289

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