Positioner. KUKA Roboter GmbH. KUKA Positioner. DKP-400 Specification. Issued: Version: Spez DKP-400 V7

Transcription

1 Positioner KUKA Roboter GmbH KUKA Positioner DKP-400 Specification KUKA Positioner Issued: Version: Spez DKP-400 V7

2 Copyright 2016 KUKA Roboter GmbH Zugspitzstraße 140 D Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter 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. Translation of the original documentation KIM-PS5-DOC Publication: Pub Spez DKP-400 en Book structure: Spez DKP-400 V6.1 Version: Spez DKP-400 V7 2 / 75 Issued: Version: Spez DKP-400 V7

3 Contents Contents 1 Introduction Industrial robot documentation Representation of warnings and notes Terms used Purpose Target group Intended use Product description Overview Description of the positioner Control and integration Description of energy supply system Description of the holder group Energy supply system, DKP-400 V Description of cable package Description of interface Energy supply system, DKP-400 V Description of cable package Description of interface Energy supply system, DKP-400 V Description of cable package Description of interface Energy supply system, DKP-400 V Description of cable package Description of interface Energy supply system, DKP-400 V Description of cable package Description of interface Technical data Technical data, overview Technical data, DKP-400 V Basic data, DKP-400 V Axis data, DKP-400 V Payloads, DKP-400 V Foundation loads, DKP-400 V Technical data, DKP-400 V Basic data, DKP-400 V Axis data, DKP-400 V Payloads, DKP-400 V Foundation loads, DKP-400 V Technical data, DKP-400 V Basic data, DKP-400 V Axis data, DKP-400 V Payloads, DKP-400 V Issued: Version: Spez DKP-400 V7 3 / 75

4 4.4.4 Foundation loads, DKP-400 V Technical data, DKP-400 V Basic data, DKP-400 V Axis data, DKP-400 V Payloads, DKP-400 V Foundation loads, DKP-400 V Technical data, DKP-400 V Basic data, DKP-400 V Axis data, DKP-400 V Payloads, DKP-400 V Foundation loads, DKP-400 V Plates and labels REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/ Stopping distances Cables and hoses of the energy supply system Control cable X76 - X Grounding cable, 70 mm 2, black US1/US2 power supply X61 - X ProfiNet cable X62 - X Air line 1/2", blue - open Air line, blue - open Air line, blue - open Ground conductor, equipotential bonding Functional ground Safety General Liability Intended use of the industrial robot EC declaration of conformity and declaration of incorporation Terms used Personnel Workspace, safety zone and danger zone Overview of protective equipment Mechanical end stops Mechanical axis range limitation (optional) Axis range monitoring (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 Applied norms and regulations / 75 Issued: Version: Spez DKP-400 V7

5 Contents 6 Planning Mounting base Face plate dimensions Transportation Transportation KUKA Service Requesting support KUKA Customer Support Index Issued: Version: Spez DKP-400 V7 5 / 75

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7 1 Introduction 1 Introduction t 1.1 Industrial robot documentation t The industrial robot documentation consists of the following parts: Documentation for the manipulator Documentation for the robot controller Operating and programming instructions for the System Software Instructions for options and accessories Parts catalog on storage medium Each of these sets of instructions is a separate document. 1.2 Representation of warnings and notes Safety These warnings are relevant to safety and must be observed. are taken. These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions These warnings mean that death or severe injuries may occur, if no precautions are taken. These warnings mean that minor injuries may occur, if no precautions are taken. These warnings mean that damage to property may occur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: 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. 1.3 Terms used Term Axis range Drive unit Description Range of an axis, in degrees, within which the robot/positioner may move. The axis range must be defined for each axis that is to be monitored. A combination of motor and gear unit. Issued: Version: Spez DKP-400 V7 7 / 75

8 Term Workspace Braking distance CE mark (CE mark) EMD Release device Danger zone KP KR C KUKA smartpad Manipulator RDC Robot system Safety zone smartpad Fixture External axis Description The robot/positioner is allowed to move within its workspace. The workspace is derived from the individual axis ranges. The braking distance is the distance covered by the robot/positioner after the stop function has been triggered and before the robot comes to a standstill. The safety requirements of all relevant EC directives have been met. All prescribed conformity assessment procedures have been carried out. The EMD (electronic mastering device) is used for mastering the positioner with the KR C4. The release device can be used to move the positioner mechanically after an accident or malfunction. The danger zone consists of the workspace and the braking distances. KUKA positioning system is a kinematic system that is controlled by the robot controller as an external axis. The shorter term positioner is used in the documentation. KUKA Robot Controller see smartpad The robot arm and the associated electrical installations Resolver Digital Converter Robot system, consisting of robot, positioner, robot controller, KUKA System Software, connecting cables and KCP. The safety zone is situated outside the danger zone. Teach pendant for the KR C4 The smartpad has all the operator control and display functions required for operating and programming the industrial robot. A customer-specific fixture adapted to the relevant application is mounted on the positioner. If the positioner is connected to the robot controller, its axes are configured as external axes of the robot. 8 / 75 Issued: Version: Spez DKP-400 V7

9 2 Purpose 2 Purpose s 2.1 Target group This documentation is aimed at users with the following knowledge and skills: Advanced knowledge of mechanical engineering Advanced knowledge of electrical and electronic systems Advanced knowledge of programming external axes Advanced knowledge of machine data Knowledge of the robot controller system For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at or can be obtained directly from our subsidiaries. 2.2 Intended use Use Misuse The intended use of the positioner is the movement and positioning of loads and workpieces. The positioner is designed exclusively for the specified applications. Use for any other or additional purpose is considered impermissible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user. Operation in accordance with the intended use also involves continuous observance of the operating instructions with particular reference to the maintenance specifications. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. The manufacturer cannot be held liable for any resulting damage. The risk lies entirely with the user. Examples of such misuse include: Transportation of persons and animals Use as a climbing aid Operation outside the permissible technical operating parameters Operation in potentially explosive environments Underground operation Changing the structure of the positioner, e.g. by drilling holes, etc., can result in damage to the components. This is considered improper use and leads to loss of guarantee and liability entitlements. The positioner is an integral part of an overall system and may only be operated in a CE-compliant system. Issued: Version: Spez DKP-400 V7 9 / 75

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11 3 Product description 3 Product description t3.1 Overview s The DKP product family contains the following positioner types, differing in terms of color and the energy supply system integrated into them. Type DKP-400 V1 DKP-400 V2 DKP-400 V3 DKP-400 V4 DKP-400 V5 Payload 400 kg Fig. 3-1: DKP-400, example 3.2 Description of the positioner Overview The positioner has two axes, which are 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). An energy supply system (e.g. for compressed air, electrical current) can be integrated into the system. In the document, the axes of the positioner are referred to as axis 1 (A1) and axis 2 (A2). In the actual application, A1 and A2 might already be assigned to different system components. Issued: Version: Spez DKP-400 V7 11 / 75

12 Fig. 3-2: Principal components, example DKP-400 V1 1 Swing frame 3 Base frame 2 Rotational axis motor 4 Tilting axis motor Base frame Swing frame The base frame is the base of the positioner. It supports the tilting axis and is bolted to the floor. The swing frame is of cast design and serves as a mount for the motor and the gear unit of the rotational axis. Two stops on the swing frame and stop blocks on the base frame limit the range of the tilting axis. This provides the energy supply system and the face plate with mechanical protection against excessive tilting. Fig. 3-3: Tilting axis, mechanical limit stops 1 Face plate 3 Stop block 2 Energy supply system 4 Stop By default, moving the stop blocks allows gradual adjustment of the tilting range from +30 /+60 /+90 to -30 /-60 / / 75 Issued: Version: Spez DKP-400 V7

13 3 Product description Special stop blocks make it possible for all stops to be set from +0 to +90 and from -0 to -90. Accessories Options The positioner can be fitted with an energy supply system. Only accessories authorized by KUKA Roboter GmbH for this positioner may be used. All items of equipment must possess the appropriate certification and declarations of conformity. No options are available for these positioner types. 3.3 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. 3-4: 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. 3.4 Description of energy supply system For use in certain production technologies, the positioner is equipped with an energy supply system installed. The energy supply system consists of a hose and cable bundle for transmitting the energy, fluids and signals typical of the technological process concerned. Each energy supply system consists of a Issued: Version: Spez DKP-400 V7 13 / 75

14 cable package and the holders for energy supply system required for attaching it to the robot. The energy supply system accommodates the cables and hoses and ensures that they are guided with minimum stress throughout the permitted turning range of the rotational axis. It is installed between the interface on the base frame and the platform. The energy supply system consists of an applicationspecific cable package, including the interface. Depending on the positioner type, the cable package contains control cables as well as hoses for compressed air and water. The energy supply system consists of the following principal components: Cable package Holder group (holder, clamp) Interface for connecting the supply lines Fig. 3-5: Components of the energy supply system, example 1 Cable package 4 Energy chain 2 Grounding cable 5 Interface 3 Current collector Further information about the energy supply systems can be found in the following sections: DKP-400 V1 (>>> 3.6 "Energy supply system, DKP-400 V1" Page 15) DKP-400 V2 (>>> 3.7 "Energy supply system, DKP-400 V2" Page 17) DKP-400 V3 (>>> 3.8 "Energy supply system, DKP-400 V3" Page 18) DKP-400 V4 (>>> 3.9 "Energy supply system, DKP-400 V4" Page 19) DKP-400 V5 (>>> 3.10 "Energy supply system, DKP-400 V5" Page 21) 3.5 Description of the holder group The holder group for the energy supply system and for the cable set consists of the following components: Snap clip 14 / 75 Issued: Version: Spez DKP-400 V7

15 3 Product description Fastening clamps Plate Bracket The snap clip is fastened to the base frame of the positioner using a plate and a bracket. The cable package is routed from the snap clip through the energy chain and then divided. Depending on the energy supply system, a grounding cable is fastened to the current collector. From the energy chain, the cables and hoses are routed through the energy supply chain to the center of the face plate and from there to the outside. Fig. 3-6: Holder group, example 1 Fastening clamp 5 Energy supply chain 2 Current collector 6 Snap clip 3 Energy chain 7 Bracket 4 Plate 3.6 Energy supply system, DKP-400 V Description of cable package The energy supply system is centered on the cable package. It consists of application-dependent hoses and cables. The interface is located at the rear of the base frame. From the interface, the cables and hoses of the energy supply system as well as the cable set for the drives are routed through the energy chain to the face plate where they are fixed in place. The grounding cable is fastened to the current collector. The remaining cables and hoses are routed below the face plate to the center of the face plate. Closed and open cables and hoses protrude from the face plate. This means that no connector is fitted to the open cables or hoses, thus allowing these cables and hoses to be adapted to the specific requirements. A strain relief device for the cables and hoses must be provided by the customer on the fixture and/or tool side. Issued: Version: Spez DKP-400 V7 15 / 75

16 Fig. 3-7: Cable package and cable set 1 Snap clip 2 Energy chain 3 Energy supply system: Control cable 4 Energy supply system: Air line 5 Energy supply system: PE conductor 6 Cable set: Motor cable A2 7 Cable set: Control cable A2 8 Energy supply system: Grounding cable 9 Energy supply system: PE conductor Description of interface The interface is located on the base frame of the positioner. The connection panel of the interface is designed and configured in accordance with the contents of the cable package. Fig. 3-8: Interface 1 Cable set: Control cable A2 2 Cable set: Motor cable A2 3 Cable set: PE conductor 4 Energy supply system: Air line 5 Energy supply system: Grounding cable 6 Energy supply system: Control cable 16 / 75 Issued: Version: Spez DKP-400 V7

17 3 Product description 3.7 Energy supply system, DKP-400 V Description of cable package The energy supply system is centered on the cable package. It consists of a grounding cable. The interface is located at the rear of the base frame. The grounding cable and the cable set are routed from the interface to the face plate through the energy chain. The grounding cable is then fastened to the current collector. Fig. 3-9: Cable package and cable set 1 Snap clip 2 Energy chain 3 Cable set: Motor cable A2 4 Cable set: Control cable A2 5 Energy supply system: Grounding cable 6 Cable set: PE conductor Description of interface The energy supply system has an interface permanently installed on the positioner. This interface is a connection panel designed and configured in accordance with the contents of the cable package. Fig. 3-10: Interface 1 Cable set: Motor cable A2 2 Cable set: Control cable A2 Issued: Version: Spez DKP-400 V7 17 / 75

18 3 Cable set: PE conductor 4 Energy supply system: Grounding cable 3.8 Energy supply system, DKP-400 V Description of cable package The energy supply system is centered on the cable package. It consists of application-dependent hoses and cables. The interface is located at the rear of the base frame. From the interface, the cables and hoses of the energy supply system as well as the cable set for the drives are routed through the energy chain to the face plate where they are fixed in place. The grounding cable is fastened to the current collector. The remaining cables and hoses are routed below the face plate to the center of the face plate. Closed and open cables and hoses protrude from the face plate. This means that no connector is fitted to the open cables or hoses, thus allowing these cables and hoses to be adapted to the specific requirements. A strain relief device for the cables and hoses must be provided by the customer on the fixture and/or tool side. Fig. 3-11: Cable package and cable set 1 Snap clip 2 Energy chain 3 Energy supply system: US1/US2 power supply 4 Energy supply system: ProfiNet 5 Energy supply system: Air line 1/2" 6 Energy supply system: Grounding cable 7 Cable set: PE conductor 8 Cable set: Motor cable A2 9 Cable set: Control cable A2 18 / 75 Issued: Version: Spez DKP-400 V7

19 3 Product description Description of interface The interface is located on the base frame of the positioner. The connection panel of the interface is designed and configured in accordance with the contents of the cable package. Fig. 3-12: Interface 1 Energy supply system: ProfiNet 2 Energy supply system: US1/US2 power supply 3 Cable set: PE conductor 4 Energy supply system: Air line 1/2" 5 Energy supply system: Grounding cable 6 Cable set: Control cable A2 7 Cable set: Motor cable A2 3.9 Energy supply system, DKP-400 V Description of cable package The energy supply system is centered on the cable package. It consists of application-dependent hoses and cables. The interface is located at the rear of the base frame. From the interface, the cables and hoses of the energy supply system as well as the cable set for the drives are routed through the energy chain to the face plate where they are fixed in place. The grounding cable is fastened to the current collector. The remaining cables and hoses are routed below the face plate to the center of the face plate. Closed and open cables and hoses protrude from the face plate. This means that no connector is fitted to the open cables or hoses, thus allowing these cables and hoses to be adapted to the specific requirements. A strain relief device for the cables and hoses must be provided by the customer on the fixture and/or tool side. Issued: Version: Spez DKP-400 V7 19 / 75

20 Fig. 3-13: Cable package and cable set 1 Snap clip 2 Energy chain 3 Energy supply system: US1/US2 power supply 4 Energy supply system: ProfiNet 5 Energy supply system: Air line, 10 mm 6 Energy supply system: Grounding cable 7 Cable set: PE conductor 8 Cable set: Motor cable A2 9 Cable set: Control cable A Description of interface The interface is located on the base frame of the positioner. The connection panel of the interface is designed and configured in accordance with the contents of the cable package. Fig. 3-14: Interface 1 Energy supply system: ProfiNet 2 Energy supply system: Air line 3 Energy supply system: US1/US2 power supply 4 Cable set: PE conductor 5 Energy supply system: Grounding cable 20 / 75 Issued: Version: Spez DKP-400 V7

21 3 Product description 6 Cable set: Control cable A2 7 Cable set: Motor cable A Energy supply system, DKP-400 V Description of cable package The energy supply system is centered on the cable package. It consists of application-dependent hoses and cables. The interface is located at the rear of the base frame. From the interface, the cables and hoses of the energy supply system as well as the cable set for the drives are routed through the energy chain to the face plate where they are fixed in place. The grounding cable is fastened to the current collector. The remaining cables and hoses are routed below the face plate to the center of the face plate. Closed and open cables and hoses protrude from the face plate. This means that no connector is fitted to the open cables or hoses, thus allowing these cables and hoses to be adapted to the specific requirements. A strain relief device for the cables and hoses must be provided by the customer on the fixture and/or tool side. Fig. 3-15: Cable package and cable set 1 Snap clip 2 Energy chain 3 Energy supply system: Control cable 4 Energy supply system: Air line, 10 mm 5 Energy supply system: Air line, 8 mm 6 Cable set: PE conductor 7 Cable set: PE conductor 8 Cable set: Motor cable A2 9 Cable set: Control cable A2 10 Energy supply system: Functional ground Issued: Version: Spez DKP-400 V7 21 / 75

22 Description of interface The interface is located on the base frame of the positioner. The connection panel of the interface is designed and configured in accordance with the contents of the cable package. Fig. 3-16: Interface 1 Cable set: Control cable A2 2 Cable set: Motor cable A2 3 Energy supply system: PE conductor 4 Cable set: PE conductor 5 Energy supply system: Air line, 10 mm 6 Energy supply system: Air line, 8 mm 7 Energy supply system: Control cable 22 / 75 Issued: Version: Spez DKP-400 V7

23 4 Technical data 4 Technical data T 4.1 Technical data, overview t The technical data for the individual positioner types can be found in the following sections: Positioner DKP-400 V1 DKP-400 V2 DKP-400 V3 DKP-400 V4 DKP-400 V5 Technical data Technical data (>>> 4.2 "Technical data, DKP-400 V1" Page 24) Plates and labels (>>> 4.7 "Plates and labels" Page 35) Stopping distances (>>> 4.9 "Stopping distances" Page 37) Technical data (>>> 4.3 "Technical data, DKP-400 V2" Page 26) Plates and labels (>>> 4.7 "Plates and labels" Page 35) Stopping distances (>>> 4.9 "Stopping distances" Page 37) Technical data (>>> 4.4 "Technical data, DKP-400 V3" Page 28) Plates and labels (>>> 4.7 "Plates and labels" Page 35) Stopping distances (>>> 4.9 "Stopping distances" Page 37) Technical data (>>> 4.5 "Technical data, DKP-400 V4" Page 31) Plates and labels (>>> 4.7 "Plates and labels" Page 35) Stopping distances (>>> 4.9 "Stopping distances" Page 37) Technical data (>>> 4.6 "Technical data, DKP-400 V5" Page 33) Plates and labels (>>> 4.7 "Plates and labels" Page 35) Stopping distances (>>> 4.9 "Stopping distances" Page 37) Issued: Version: Spez DKP-400 V7 23 / 75

24 4.2 Technical data, DKP-400 V Basic data, DKP-400 V1 Basic data Ambient conditions DKP-400 V1 Number of axes 2 Pose repeatability (ISO 9283) ± 0.06 mm Weight Rated payload Protection rating Sound level Mounting position Default color Controller Footprint approx. 300 kg 400 kg IP67 < 70 db (A) Floor Humidity class (EN 60204) - Classification of environmental conditions 3K3 (EN ) Ambient temperature Base frame: pebble gray (RAL 7032); Moving parts: orange (RAL 2003) KR C4 835 mm x 618 mm During operation 5 C to 40 C (278 K to 313 K) During storage/transportation -40 C to 60 C (233 K to 333 K) Axis data, DKP-400 V1 Axis data Direction of rotation Range of motion A1 - A2 - Range of motion with energy supply system A1 ±90 A2 ±185 Speed with rated payload A /s A2 126 /s The orientation of a rotational axis is defined as seen from the motor side: + clockwise - counterclockwise The direction of motion and the arrangement of the individual axes (A1 tilting axis, A2 rotational axis) may be noted from the following diagram (>>> Fig. 4-1 ). 24 / 75 Issued: Version: Spez DKP-400 V7

25 4 Technical data Fig. 4-1: Directions of rotation Working envelope The working envelope must be defined by the customer, taking the projectspecific dimensions into consideration Payloads, DKP-400 V1 Payloads Maximum load torque A1 A2 Mass moment of inertia A1 A Nm 750 Nm 170 kgm² 64 kgm² Foundation loads, DKP-400 V1 Foundation loads The specified forces and torques already include the maximum payload and the inertia force (weight) of the positioner. Fig. 4-2: Foundation loads Vertical force F(v) F(v normal) F(v max) Tilting moment M(k) M(k normal) 7000 N 8750 N 1100 Nm Issued: Version: Spez DKP-400 V7 25 / 75

26 M(k max) Torque about axis 1 M(r) M(r normal) M(r max) 1600 Nm 1900 Nm 3900 Nm 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. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 4.3 Technical data, DKP-400 V Basic data, DKP-400 V2 Basic data Ambient conditions DKP-400 V2 Number of axes 2 Pose repeatability (ISO 9283) ± 0.06 mm Weight Rated payload Protection rating Sound level Mounting position Default color Controller Footprint approx. 300 kg 400 kg IP67 < 70 db (A) Floor Humidity class (EN 60204) - Classification of environmental conditions 3K3 (EN ) Ambient temperature Base frame: pebble gray (RAL 7032); Moving parts: orange (RAL 2003) KR C4 835 mm x 618 mm During operation 5 C to 40 C (278 K to 313 K) During storage/transportation -40 C to 60 C (233 K to 333 K) Axis data, DKP-400 V2 Axis data Range of motion A1 - A2 - Range of motion with energy supply system A1 ±90 A2 Infinite 26 / 75 Issued: Version: Spez DKP-400 V7

27 4 Technical data Speed with rated payload A1 A /s 126 /s Direction of rotation The orientation of a rotational axis is defined as seen from the motor side: + clockwise - counterclockwise The direction of motion and the arrangement of the individual axes (A1 tilting axis, A2 rotational axis) may be noted from the following diagram (>>> Fig. 4-3 ). Fig. 4-3: Directions of rotation 1 A7 (tilting axis) with positive and negative direction of rotation 2 Cross hairs for calibrating an external kinematic system 3 A8 (rotational axis) with positive and negative direction of rotation Further information about calibrating external kinematic systems is contained in the operating and programming instructions for the KUKA System Software (KSS). Working envelope The working envelope must be defined by the customer, taking the projectspecific dimensions into consideration Payloads, DKP-400 V2 Payloads Maximum load torque A1 A2 Mass moment of inertia A1 A Nm 750 Nm 170 kgm² 64 kgm² Foundation loads, DKP-400 V2 Foundation loads The specified forces and torques already include the maximum payload and the inertia force (weight) of the positioner. Issued: Version: Spez DKP-400 V7 27 / 75

28 Fig. 4-4: Foundation loads Vertical force F(v) F(v normal) F(v max) Tilting moment M(k) M(k normal) M(k max) Torque about axis 1 M(r) M(r normal) M(r max) 7000 N 8750 N 1100 Nm 1600 Nm 1900 Nm 3900 Nm 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. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 4.4 Technical data, DKP-400 V Basic data, DKP-400 V3 Basic data DKP-400 V3 Number of axes 2 Pose repeatability (ISO 9283) ± 0.06 mm Weight approx. 300 kg Rated payload 400 kg Protection rating IP67 Sound level < 70 db (A) Mounting position Floor 28 / 75 Issued: Version: Spez DKP-400 V7

29 4 Technical data DKP-400 V3 Default color Base frame: light gray (RAL 7035); Moving parts: orange (RAL 2003) Controller KR C4 Footprint 835 mm x 618 mm Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions 3K3 (EN ) Ambient temperature During operation 5 C to 40 C (278 K to 313 K) During storage/transportation -40 C to 60 C (233 K to 333 K) Axis data, DKP-400 V3 Axis data Direction of rotation Range of motion A1 - A2 - Range of motion with energy supply system A1 ±90 A2 ±185 Speed with rated payload A /s A2 126 /s The orientation of a rotational axis is defined as seen from the motor side: + clockwise - counterclockwise The direction of motion and the arrangement of the individual axes (A1 tilting axis, A2 rotational axis) may be noted from the following diagram (>>> Fig. 4-5 ). Fig. 4-5: Directions of rotation Working envelope The working envelope must be defined by the customer, taking the projectspecific dimensions into consideration. Issued: Version: Spez DKP-400 V7 29 / 75

30 4.4.3 Payloads, DKP-400 V3 Payloads Maximum load torque A1 A2 Mass moment of inertia A1 A Nm 750 Nm 170 kgm² 64 kgm² Foundation loads, DKP-400 V3 Foundation loads The specified forces and torques already include the maximum payload and the inertia force (weight) of the positioner. Fig. 4-6: Foundation loads Vertical force F(v) F(v normal) F(v max) Tilting moment M(k) M(k normal) M(k max) Torque about axis 1 M(r) M(r normal) M(r max) 7000 N 8750 N 1100 Nm 1600 Nm 1900 Nm 3900 Nm 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. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 30 / 75 Issued: Version: Spez DKP-400 V7

31 4 Technical data 4.5 Technical data, DKP-400 V Basic data, DKP-400 V4 Basic data Ambient conditions DKP-400 V4 Number of axes 2 Pose repeatability (ISO 9283) ± 0.06 mm Weight approx. 300 kg Rated payload 400 kg Protection rating IP67 Sound level < 70 db (A) Mounting position Floor Default color Counterbalancing system: black (RAL 9005) Controller KR C4 Footprint 835 mm x 618 mm Humidity class (EN 60204) - Classification of environmental conditions 3K3 (EN ) Ambient temperature During operation 5 C to 40 C (278 K to 313 K) During storage/transportation -40 C to 60 C (233 K to 333 K) Axis data, DKP-400 V4 Axis data Direction of rotation Range of motion A1 - A2 - Range of motion with energy supply system A1 ±90 A2 ±185 Speed with rated payload A /s A2 126 /s The orientation of a rotational axis is defined as seen from the motor side: + clockwise - counterclockwise The direction of motion and the arrangement of the individual axes (A1 tilting axis, A2 rotational axis) may be noted from the following diagram (>>> Fig. 4-7 ). Issued: Version: Spez DKP-400 V7 31 / 75

32 Fig. 4-7: Directions of rotation Working envelope The working envelope must be defined by the customer, taking the projectspecific dimensions into consideration Payloads, DKP-400 V4 Payloads Maximum load torque A1 A2 Mass moment of inertia A1 A Nm 750 Nm 170 kgm² 64 kgm² Foundation loads, DKP-400 V4 Foundation loads The specified forces and torques already include the maximum payload and the inertia force (weight) of the positioner. Fig. 4-8: Foundation loads Vertical force F(v) F(v normal) F(v max) Tilting moment M(k) M(k normal) 7000 N 8750 N 1100 Nm 32 / 75 Issued: Version: Spez DKP-400 V7

33 4 Technical data M(k max) Torque about axis 1 M(r) M(r normal) M(r max) 1600 Nm 1900 Nm 3900 Nm 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. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 4.6 Technical data, DKP-400 V Basic data, DKP-400 V5 Basic data Ambient conditions DKP-400 V5 Number of axes 2 Pose repeatability (ISO 9283) ± 0.06 mm Weight approx. 300 kg Rated payload 400 kg Protection rating IP67 Sound level < 70 db (A) Mounting position Floor Default color Base frame: anthracite gray (RAL 7016); Moving parts: orange (RAL 2003) Controller KR C4 Footprint 835 mm x 618 mm Humidity class (EN 60204) - Classification of environmental conditions 3K3 (EN ) Ambient temperature During operation 5 C to 40 C (278 K to 313 K) During storage/transportation -40 C to 60 C (233 K to 333 K) Axis data, DKP-400 V5 Axis data Range of motion A1 - A2 - Range of motion with energy supply system A1 ±90 A2 ±185 Issued: Version: Spez DKP-400 V7 33 / 75

34 Speed with rated payload A1 A /s 126 /s Direction of rotation The orientation of a rotational axis is defined as seen from the motor side: + clockwise - counterclockwise The direction of motion and the arrangement of the individual axes (A1 tilting axis, A2 rotational axis) may be noted from the following diagram (>>> Fig. 4-9 ). Fig. 4-9: Directions of rotation Working envelope The working envelope must be defined by the customer, taking the projectspecific dimensions into consideration Payloads, DKP-400 V5 Payloads Maximum load torque A1 A2 Mass moment of inertia A1 A Nm 750 Nm 170 kgm² 64 kgm² Foundation loads, DKP-400 V5 Foundation loads The specified forces and torques already include the maximum payload and the inertia force (weight) of the positioner. 34 / 75 Issued: Version: Spez DKP-400 V7

35 4 Technical data Fig. 4-10: Foundation loads Vertical force F(v) F(v normal) F(v max) Tilting moment M(k) M(k normal) M(k max) Torque about axis 1 M(r) M(r normal) M(r max) 7000 N 8750 N 1100 Nm 1600 Nm 1900 Nm 3900 Nm 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. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 4.7 Plates and labels Plates and labels 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. Issued: Version: Spez DKP-400 V7 35 / 75

36 Fig. 4-11: Location of plates and labels Item 1 Description 2 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! 3 Do not slacken screwed connection Do not slacken screwed connection! Observe safety instructions and assembly instructions! 4 Direction of translation/rotation The label shows the plus and minus directions of the corresponding translational/rotational axis. High voltage Any improper handling can lead to contact with current-carrying components. Electric shock hazard! 36 / 75 Issued: Version: Spez DKP-400 V7

37 4 Technical data Item 5 Description 6 Hot surface During operation of the robot, surface temperatures may be reached that could result in burn injuries. Protective gloves must be worn! 7 Work on the positioner Before start-up, transportation or maintenance, read and follow the assembly and operating instructions. Identification plate Content according to Machinery Directive. 4.8 REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/2006 On the basis of the information provided by our suppliers, this product and its components contain no substances included on the Candidate List of Substances of Very High Concern (SVHCs) in a concentration exceeding 0.1 percent by mass. 4.9 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 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 Issued: Version: Spez DKP-400 V7 37 / 75

38 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. Stopping distance ( ) Positioner STOP 0 A1 A2 DKP-400 V DKP-400 V DKP-400 V DKP-400 V DKP-400 V Cables and hoses of the energy supply system Overview The following hoses and/or electrical cables are contained in the respective cable packages: Cable/hose DKP-400 V1 Control cable, X76-X86 (>>> "Control cable X76 - X86" Page 39) Grounding cable, 70 mm 2, black (>>> "Grounding cable, 70 mm 2, black" Page 41) Air line, blue - open (>>> "Air line 1/2", blue - open" Page 42) Ground conductor, equipotential bonding (>>> "Ground conductor, equipotential bonding" Page 43) DKP-400 V2 Grounding cable, 70 mm 2, black (>>> "Grounding cable, 70 mm 2, black" Page 41) Ground conductor, equipotential bonding (>>> "Ground conductor, equipotential bonding" Page 43) DKP-400 V3 US1/US2 power supply X61-X71 (>>> "US1/US2 power supply X61 - X71" Page 41) Connection X76 Insulator AIR Ground conductor connection Insulator Ground conductor connection X61 38 / 75 Issued: Version: Spez DKP-400 V7

39 4 Technical data Cable/hose ProfiNet cable X62-X72 (>>> "ProfiNet cable X62 - X72" Page 41) Grounding cable, 70 mm 2, black (>>> "Grounding cable, 70 mm 2, black" Page 41) Air line 1/2", blue - open (>>> "Air line 1/2", blue - open" Page 42) Ground conductor, equipotential bonding (>>> "Ground conductor, equipotential bonding" Page 43) DKP-400 V4 US1/US2 power supply X61-X71 (>>> "US1/US2 power supply X61 - X71" Page 41) ProfiNet cable X62-X72 (>>> "ProfiNet cable X62 - X72" Page 41) Grounding cable, 70 mm 2, black (>>> "Grounding cable, 70 mm 2, black" Page 41) Air line, blue - open, 10 mm (>>> "Air line, blue - open" Page 42) Ground conductor, equipotential bonding (>>> "Ground conductor, equipotential bonding" Page 43) DKP-400 V5 Control cable, X76-X86 (>>> "Control cable X76 - X86" Page 39) Air line, blue - open, 10 mm (>>> "Air line, blue - open" Page 42) Air line, blue - open, 8 mm (>>> "Air line, blue - open" Page 43) Ground conductor, equipotential bonding (>>> "Ground conductor, equipotential bonding" Page 43) Functional ground (>>> "Functional ground" Page 43) Connection X62 Insulator AIR Ground conductor connection X61 X62 Insulator L1 Ground conductor connection X64 L1 SG XL64 Ground conductor connection Control cable X76 - X86 Configuration 23x 1 mm 2 Rated voltage 2x 1 mm V AC Issued: Version: Spez DKP-400 V7 39 / 75

40 Current Connection on interface Connection on face plate Minimum bending radius Protection rating EN (derating factors must be taken into account) HAN 25 D connector with crimp terminal Hood, M25 10x outer diameter IP65 Fig. 4-12: Control cable, X76 - X86 40 / 75 Issued: Version: Spez DKP-400 V7

41 4 Technical data Grounding cable, 70 mm 2, black Configuration Connection on interface Connection on face plate Minimum bending radius 1x 70 mm 2, black M10 ring cable lug M10 ring cable lug 10x outer diameter Fig. 4-13: Grounding cable, 70 mm 2, black US1/US2 power supply X61 - X71 Configuration Rated voltage Current Connection on interface Connection on face plate Minimum bending radius Protection rating 2x (2x AWG22) 30 V DC EN (derating factors must be taken into account) M12, A-coded, connector/male (connector in bypack) M12, A-coded, female/coupling (connector in bypack) 10x outer diameter IP65 Fig. 4-14: US1/US2 power supply ProfiNet cable X62 - X72 Configuration 5x 0.34 mm 2 Connection on interface Connection on face plate Minimum bending radius M12, A-coded, connector/male M12, A-coded, female/coupling 10x outer diameter Issued: Version: Spez DKP-400 V7 41 / 75

42 Fig. 4-15: ProfiNet cable X67 - X Air line 1/2", blue - open Hose line Connection on interface Connection on face plate Rated pressure max. Minimum bending radius Permissible thermal loading Plug-in hose 1/2", blue Bulkhead union, M22x1.5, straight Open 2.0 Mp (20 bar) 10x outer diameter 243 K K (-30 C C) Fig. 4-16: Air line, blue, open Air line, blue - open Hose line Connection on interface Connection on face plate Rated pressure max. Polyurethane hose 10 mm Open Open 2.0 Mp (20 bar) 42 / 75 Issued: Version: Spez DKP-400 V7

43 4 Technical data Minimum bending radius Permissible thermal loading 10x outer diameter 243 K to 383 K (-30 C to +80 C) Air line, blue - open Hose line Connection on interface Connection on face plate Rated pressure max. Minimum bending radius Permissible thermal loading Polyurethane hose 8 mm Open Open 2.0 Mp (20 bar) 10x outer diameter 243 K to 383 K (-30 C to +80 C) Ground conductor, equipotential bonding Configuration 1x 10 mm 2 Connection 1 Connection 2 Minimum bending radius Ring cable lug, 8 mm Ring cable lug, 8 mm 10x outer diameter Fig. 4-17: Ground conductor Functional ground Configuration 1x 10 mm 2 Connection 1 Connection 2 Minimum bending radius Ring cable lug, 8 mm Ring cable lug, 8 mm 10x outer diameter Fig. 4-18: Ground conductor, open Issued: Version: Spez DKP-400 V7 43 / 75

44 44 / 75 Issued: Version: Spez DKP-400 V7

45 5 Safety 5 Safety f t y 5.1 General 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 Liability 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 designated 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 affecting safety must be rectified immediately. Safety information Safety information cannot be held against KUKA Roboter GmbH. 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 KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, 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. Issued: Version: Spez DKP-400 V7 45 / 75

46 5.1.2 Intended use of the industrial robot The industrial robot is intended exclusively for the use designated in the Purpose chapter of the operating instructions or assembly instructions. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. The manufacturer is not liable for any damage resulting from such misuse. The risk lies entirely with the user. Operation of the industrial robot 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. This includes e.g.: Transportation of persons and animals Use as a climbing aid Operation outside the specified operating parameters Use in potentially explosive environments Operation without additional safeguards Outdoor operation Underground operation 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 an assessment of conformity. Declaration of conformity Declaration of incorporation The system integrator must issue a declaration of conformity for the complete system in accordance with the Machinery Directive. The 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. The partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery is not allowed until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. 46 / 75 Issued: Version: Spez DKP-400 V7

47 5 Safety Terms used Term Axis range Stopping distance Workspace Operator (User) Danger zone Service life KCP KUKA smartpad Manipulator Safety zone smartpad Stop category 0 Stop category 1 Stop category 2 System integrator (plant integrator) T1 T2 External axis Description Range of each axis, in degrees or millimeters, within which it may move. The axis range must be defined for each axis. Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. The manipulator is allowed to move within its workspace. The workspace is derived from the individual axis ranges. The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. The danger zone consists of the workspace and the stopping distances. The service life of a safety-relevant component begins at the time of delivery of the component to the customer. The service life is not affected by whether the component is used in a robot controller or elsewhere or not, as safety-relevant components are also subject to aging during storage. KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. see smartpad The robot arm and the associated electrical installations The safety zone is situated outside the danger zone. Teach pendant for the KR C4 The smartpad has all the operator control and display functions required for operating and programming the industrial robot. The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called STOP 0 in this document. The manipulator and any external axes (optional) perform path-maintaining braking. The drives are deactivated after 1 s and the brakes are applied. Note: This stop category is called STOP 1 in this document. The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a normal braking ramp. Note: This stop category is called STOP 2 in this document. System integrators are people who safely integrate the industrial robot into a complete system and commission it. Test mode, Manual Reduced Velocity (<= 250 mm/s) Test mode, Manual High Velocity (> 250 mm/s permissible) Motion axis which is not part of the manipulator but which is controlled using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex. 5.2 Personnel The following persons or groups of persons are defined for the industrial robot: User Issued: Version: Spez DKP-400 V7 47 / 75

48 Personnel All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety chapter. User Personnel The user must observe the labor laws and regulations. This includes e.g.: The user must comply with his monitoring obligations. The user must carry out briefing at defined intervals. Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. Personnel includes: System integrator Operators, subdivided into: Start-up, maintenance and service personnel Operating personnel Cleaning personnel Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in the operating or assembly instructions for the relevant component of the industrial robot and only by personnel specially trained for this purpose. System integrator Operator 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 risk assessment Implementing the required safety functions and safeguards Issuing the declaration of conformity Attaching the CE mark Creating the operating instructions for the complete system The operator must meet the following preconditions: The operator must be trained for the work to be carried out. Work on the industrial robot must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. Work on the electrical and mechanical equipment of the industrial robot may only be carried out by specially trained personnel. 5.3 Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards. 48 / 75 Issued: Version: Spez DKP-400 V7

49 5 Safety The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must be safeguarded by means of physical safeguards to prevent danger to persons or the risk of material damage. 5.4 Overview of protective equipment The protective equipment of the mechanical component may include: Mechanical end stops Mechanical axis range limitation (optional) Axis range monitoring (optional) Release device (optional) Labeling of danger areas Not all equipment is relevant for every mechanical component 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. If the manipulator or an external axis hits an obstruction or a mechanical end stop or axis range limitation, the manipulator can no longer be operated safely. The manipulator must be taken out of operation and KUKA Roboter GmbH must be consulted before it is put back into operation Mechanical axis range limitation (optional) Some manipulators can be fitted with mechanical axis range limitation in axes A1 to A3. The adjustable axis range 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 range 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 range limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There must be no shearing or crushing hazards at the loading and transfer areas. This option is not available for all robot models. Information on specific robot models can be obtained from KUKA Roboter GmbH Axis range monitoring (optional) Some manipulators can be fitted with dual-channel axis range monitoring systems in main axes A1 to A3. The positioner axes may be fitted with additional axis range monitoring systems. The safety zone for an axis can be adjusted Issued: Version: Spez DKP-400 V7 49 / 75

50 and monitored using an axis range monitoring system. This increases personal safety and protection of the system. This option is not available for the KR C4. This option is not available for all robot models. Information on specific robot models can be obtained from KUKA Roboter GmbH Options for moving the manipulator without drive energy The system user is responsible for ensuring that the training of personnel with regard to the response to emergencies or exceptional situations also includes how the manipulator can be moved without drive energy. Description The following options are 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. 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 requested from KUKA Roboter GmbH. Moving the manipulator without drive energy can damage the motor brakes of the axes concerned. The motor must be replaced if the brake has been damaged. The manipulator may therefore be moved without drive energy only in emergencies, e.g. for rescuing persons 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. 50 / 75 Issued: Version: Spez DKP-400 V7

51 5 Safety 5.5 Safety measures 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 possible, the manipulator and external axes must be secured by appropriate means. In the absence of operational safety functions and safeguards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deactivated, the industrial robot may not be operated. arm is prohibited! Standing underneath the robot arm can cause death or injuries. For this reason, standing underneath the robot The motors reach temperatures during operation which can cause burns to the skin. Contact must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. 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. The operator must ensure that decoupled KCPs/smart- PADs are immediately removed from the system and stored out of sight and reach of personnel working on the industrial robot. This serves to prevent operational and non-operational EMERGENCY STOP devices from becoming interchanged. Failure to observe this precaution may result in death, severe injuries or considerable damage to property. 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. Issued: Version: Spez DKP-400 V7 51 / 75

52 Modifications Faults After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes modifications to the software and configuration settings. The following tasks must be carried out in the case of faults in the industrial robot: 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. Eliminate the fault and carry out a function test Transportation Manipulator Robot controller External axis (optional) 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. 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. 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 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. The passwords for logging onto the KUKA System Software as Expert and Administrator must be changed before start-up and must only be communicated to authorized personnel. 52 / 75 Issued: Version: Spez DKP-400 V7

53 5 Safety The robot controller is preconfigured for the specific industrial robot. If cables are interchanged, the manipulator and the external axes (optional) may receive incorrect data and can thus cause personal injury or material damage. If a system consists of more than one manipulator, always connect the connecting cables to the manipulators and their corresponding robot controllers. If additional components (e.g. cables), which are not part of the scope of supply of KUKA Roboter GmbH, are integrated into the industrial robot, the user is responsible for ensuring that these components do not adversely affect or disable safety functions. If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form, which may cause damage to the electrical components. Do not put the robot controller into operation until the internal temperature of the cabinet has adjusted to the ambient temperature. 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. 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. In the case of such damage, the affected components must be exchanged. In particular, the motor and counterbalancing system must be checked carefully. External forces can cause non-visible damage. For example, it can lead to a gradual loss of drive power from the motor, resulting in unintended movements of the manipulator. Death, injuries or considerable damage to property may otherwise result. There are no foreign bodies or loose parts on the industrial robot. All required safety equipment is correctly installed and operational. The power supply ratings of the industrial robot correspond to the 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. Machine data It must be ensured that the rating plate on the robot controller has the same machine data as those entered in the declaration of incorporation. The machine data on the rating plate of the manipulator and the external axes (optional) must be entered during start-up. The industrial robot must not be moved if incorrect machine data are loaded. Death, severe injuries or considerable damage to property may otherwise result. The correct machine data must be loaded. Issued: Version: Spez DKP-400 V7 53 / 75

54 5.5.4 Manual mode Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes: Jog mode Teaching Programming Program verification The following must be taken into consideration in manual mode: If the drives are not required, they must be switched off to prevent the manipulator or the external axes (optional) from being moved unintentionally. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence. Workpieces, tooling and other objects must not become jammed as a result of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off. All setup work must be carried out, where possible, from outside the safeguarded area. If the setup work has to be carried out inside the safeguarded area, the following must be taken into consideration: In Manual Reduced Velocity mode (T1): If it can be avoided, there must be no other persons inside the safeguarded area. If it is necessary for there to be several persons inside the safeguarded area, the following must be observed: Each person must have an enabling device. All persons must have an unimpeded view of the industrial robot. Eye-contact between all persons must be possible at all times. The operator must be so positioned that he can see into the danger area and get out of harm s way. In Manual High Velocity mode (T2): This mode may only be used if the application requires a test at a velocity higher than possible in T1 mode. Teaching and programming are not permissible in this operating mode. Before commencing the test, the operator must ensure that the enabling devices are operational. The operator must be positioned outside the danger zone. There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this Automatic mode Automatic mode is only permissible in compliance with the following safety measures: All safety equipment and safeguards are present and operational. There are no persons in the system. The defined working procedures are adhered to. 54 / 75 Issued: Version: Spez DKP-400 V7

55 5 Safety If the manipulator or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered Maintenance and repair After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on the 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. Before work is commenced on live parts of the robot system, the main switch must be turned off and secured against being switched on again. The system must then be checked to ensure that it is deenergized. It is not sufficient, before commencing work on live parts, to execute an EMERGENCY STOP or a safety stop, or to switch off the drives, as this does not disconnect the robot system from the mains power supply. Parts remain energized. Death or severe injuries may result. Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Roboter GmbH 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. Voltages in excess of 50 V (up to 600 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. Water and dust must be prevented from entering the robot controller. Issued: Version: Spez DKP-400 V7 55 / 75

56 Counterbalancing system Hazardous substances Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbalancing system. The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment and, as such, are subject to obligatory equipment monitoring and the provisions of the Pressure Equipment Directive. The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment. Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before commissioning at the installation site. The following safety measures must be carried out when working on the counterbalancing system: The manipulator assemblies supported by the counterbalancing systems must be secured. Work on the counterbalancing systems must only be carried out by qualified personnel. The following safety measures must be carried out when handling hazardous substances: Avoid prolonged and repeated intensive contact with the skin. Avoid breathing in oil spray or vapors. Clean skin and apply skin cream. To ensure safe use of our products, we recommend regularly requesting up-to-date safety data sheets for hazardous substances Decommissioning, storage and disposal The industrial robot must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards. 5.6 Applied norms and regulations Name Definition Edition 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) /30/EU EMC Directive: Directive 2014/30/EC of the European Parliament and of the Council of 26 February 2014 on the approximation of the laws of the Member States concerning electromagnetic compatibility / 75 Issued: Version: Spez DKP-400 V7

57 5 Safety 2014/68/EC 97/23/EC EN ISO EN ISO EN ISO EN ISO EN ISO EN A1 EN EN A1 EN A1 Pressure Equipment Directive: Directive 2014/68/EC of the European Parliament and of the Council of 15 May 2014 on the approximation of the laws of the Member States concerning pressure equipment (Only applicable for robots with hydropneumatic counterbalancing system.) This directive is valid from the 19/07/2016 on. Pressure Equipment Directive: Directive 97/23/EC of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment (Only applicable for robots with hydropneumatic counterbalancing system.) This directive is valid until 18/07/2016. Safety of machinery: Emergency stop - Principles for design Safety of machinery: Safety-related parts of control systems - Part 1: General principles of design Safety of machinery: Safety-related parts of control systems - Part 2: Validation Safety of machinery: General principles of design, risk assessment and risk reduction Industrial robots Safety requirements Part 1: Robot Note: Content equivalent to ANSI/RIA R , Part 1 Safety of machinery: Ergonomic design principles - Part 1: Terms and general principles Electromagnetic compatibility (EMC): Part 6-2: Generic standards; Immunity for industrial environments Electromagnetic compatibility (EMC): Part 6-4: Generic standards; Emission standard for industrial environments Safety of machinery: Electrical equipment of machines - Part 1: General requirements Issued: Version: Spez DKP-400 V7 57 / 75

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59 6 Planning 6 Planning 6.1 Mounting base The mounting base is used to fasten the positioner to the floor. 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 bedplates and the concrete foundation. The quality of the concrete must meet the requirements of the following standard: C20/25 according to DIN EN 206-1:2001/DIN :2008 To ensure that the anchor forces are safely transmitted to the foundation, observe the dimensions for concrete foundations specified in the following illustration. Fig. 6-1: Cross-section of foundations 1 Base frame 2 Grade of concrete in accordance with DIN 1045 B25 3 Minimum depth of concrete 4 Min. distance to edge 5 Concrete foundation Issued: Version: Spez DKP-400 V7 59 / 75

60 Hole pattern Fig. 6-2: Hole pattern for mounting base 6.2 Face plate dimensions The face plate has the dimensions specified in the following diagram. 60 / 75 Issued: Version: Spez DKP-400 V7

61 6 Planning Fig. 6-3: Hole pattern for face plate Issued: Version: Spez DKP-400 V7 61 / 75

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63 7 Transportation 7 Transportation T s 7.1 Transportation t t 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 before transportation. The positioner may tip during transportation. Risk of personal injury and damage to property. The positioner must be secured to prevent it from tipping. It is forbidden to pick up the positioner in any other way using a crane. Use of unsuitable handling equipment may result in damage to the positioner or injury to persons. Only use authorized handling equipment with a sufficient load-bearing capacity. The positioner may only be transported in the manner specified here. 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. Transport position The positioner must be in the transport position (>>> Fig. 7-1 ) before it is transported. Fig. 7-1: Transport position 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. Issued: Version: Spez DKP-400 V7 63 / 75

64 Fig. 7-2: Transport dimensions Transportation using lifting tackle The positioner is transported for installation on the floor using lifting tackle. The lifting tackle must be attached to the face plate by means of 2 M16 eyebolts with two 17-DIN7349 washers each as shown in the illustration (>>> Fig. 7-3 ). Fig. 7-3: Transportation using lifting tackle 1 Crane 3 Eyebolt 2 Lifting tackle 4 Face plate 64 / 75 Issued: Version: Spez DKP-400 V7

65 8 KUKA Service 8 KUKA Service A 8.1 Requesting support v Introduction Information This documentation provides information on operation and operator control, and provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary. The following information is required for processing a support request: Description of the problem, including information about the duration and frequency of the fault As comprehensive information as possible 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 Diagnostic package KRCDiag Additionally for KUKA Sunrise: Existing projects including applications For versions of KUKA System Software older than V8: Archive of the software (KRCDiag is not yet available here.) Application used External axes used 8.2 KUKA Customer Support Availability KUKA Customer Support is available in many countries. Please do not hesitate to contact us if you have any questions. Argentina Ruben Costantini S.A. (Agency) Luis Angel Huergo Parque Industrial 2400 San Francisco (CBA) Argentina Tel Fax [email protected] Australia KUKA Robotics Australia Pty Ltd 45 Fennell Street Port Melbourne VIC 3207 Australia Tel [email protected] Issued: Version: Spez DKP-400 V7 65 / 75

66 Belgium KUKA Automatisering + Robots N.V. Centrum Zuid Houthalen Belgium Tel Fax [email protected] Brazil KUKA Roboter do Brasil Ltda. Travessa Claudio Armando, nº 171 Bloco 5 - Galpões 51/52 Bairro Assunção CEP São Bernardo do Campo - SP Brazil Tel Fax [email protected] Chile Robotec S.A. (Agency) Santiago de Chile Chile Tel Fax [email protected] China KUKA Robotics China Co., Ltd. No. 889 Kungang Road Xiaokunshan Town Songjiang District Shanghai P. R. China Tel Fax [email protected] Germany KUKA Roboter GmbH Zugspitzstr Augsburg Germany Tel Fax [email protected] 66 / 75 Issued: Version: Spez DKP-400 V7

67 8 KUKA Service France KUKA Automatisme + Robotique SAS Techvallée 6, Avenue du Parc Villebon S/Yvette France Tel Fax [email protected] India KUKA Robotics India Pvt. Ltd. Office Number-7, German Centre, Level 12, Building No. - 9B DLF Cyber City Phase III Gurgaon Haryana India Tel Fax [email protected] Italy KUKA Roboter Italia S.p.A. Via Pavia 9/a - int Rivoli (TO) Italy Tel Fax [email protected] Japan KUKA Robotics Japan K.K. YBP Technical Center 134 Godo-cho, Hodogaya-ku Yokohama, Kanagawa Japan Tel Fax [email protected] Canada KUKA Robotics Canada Ltd Maritz Drive - Unit 4 Mississauga L5W 0A1 Ontario Canada Tel Fax [email protected] Issued: Version: Spez DKP-400 V7 67 / 75

68 Korea KUKA Robotics Korea Co. Ltd. RIT Center 306, Gyeonggi Technopark Sa 3-dong, Sangnok-gu Ansan City, Gyeonggi Do Korea Tel Fax Malaysia KUKA Robot Automation (M) Sdn Bhd South East Asia Regional Office No. 7, Jalan TPP 6/6 Taman Perindustrian Puchong Puchong Selangor Malaysia Tel. +60 (03) Fax +60 (03) Mexico KUKA de México S. de R.L. de C.V. Progreso #8 Col. Centro Industrial Puente de Vigas Tlalnepantla de Baz Estado de México Mexico Tel Fax Norway KUKA Sveiseanlegg + Roboter Sentrumsvegen Hov Norway Tel Fax [email protected] Austria KUKA Roboter CEE GmbH Gruberstraße Linz Austria Tel Fax [email protected] 68 / 75 Issued: Version: Spez DKP-400 V7

69 8 KUKA Service Poland KUKA Roboter Austria GmbH Spółka z ograniczoną odpowiedzialnością Oddział w Polsce Ul. Porcelanowa Katowice Poland Tel or -14 Fax [email protected] Portugal KUKA Robots IBÉRICA, S.A. Rua do Alto da Guerra n 50 Armazém Setúbal Portugal Tel Fax [email protected] Russia KUKA Robotics RUS Werbnaja ul. 8A Moskau Russia Tel Fax [email protected] Sweden KUKA Svetsanläggningar + Robotar AB A. Odhners gata Västra Frölunda Sweden Tel Fax [email protected] Switzerland KUKA Roboter Schweiz AG Industriestr Neuenhof Switzerland Tel Fax [email protected] Issued: Version: Spez DKP-400 V7 69 / 75

70 Spain KUKA Robots IBÉRICA, S.A. Pol. Industrial Torrent de la Pastera Carrer del Bages s/n Vilanova i la Geltrú (Barcelona) Spain Tel Fax [email protected] South Africa Jendamark Automation LTD (Agency) 76a York Road North End 6000 Port Elizabeth South Africa Tel Fax Taiwan KUKA Robot Automation Taiwan Co., Ltd. No. 249 Pujong Road Jungli City, Taoyuan County 320 Taiwan, R. O. C. Tel Fax [email protected] Thailand KUKA Robot Automation (M)SdnBhd Thailand Office c/o Maccall System Co. Ltd. 49/9-10 Soi Kingkaew 30 Kingkaew Road Tt. Rachatheva, A. Bangpli Samutprakarn Thailand Tel Fax [email protected] Czech Republic KUKA Roboter Austria GmbH Organisation Tschechien und Slowakei Sezemická 2757/ Praha Horní Počernice Czech Republic Tel Fax [email protected] 70 / 75 Issued: Version: Spez DKP-400 V7

71 8 KUKA Service Hungary KUKA Robotics Hungaria Kft. Fö út Taksony Hungary Tel Fax USA KUKA Robotics Corporation Shelby Parkway Shelby Township Michigan USA Tel Fax UK KUKA Robotics UK Ltd Great Western Street Wednesbury West Midlands WS10 7LL UK Tel Fax Issued: Version: Spez DKP-400 V7 71 / 75

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73 Index Index Numbers 2006/42/EC /30/EU /68/EC 57 95/16/EC 56 97/23/EC 57 A Accessories 13, 45 Air line, blue - open 42, 43 ANSI/RIA R Applied norms and regulations 56 Automatic mode 54 Axis data 24, 26, 29, 31, 33 Axis data, DKP-400 V1 24 Axis data, DKP-400 V2 26 Axis data, DKP-400 V3 29 Axis data, DKP-400 V4 31 Axis data, DKP-400 V5 33 Axis range 7, 47 Axis range limitation 49 Axis range monitoring 49 B Base frame 12 Basic data, DKP-400 V1 24 Basic data, DKP-400 V2 26 Basic data, DKP-400 V3 28 Basic data, DKP-400 V4 31 Basic data, DKP-400 V5 33 Brake defect 51 Brake release device 50 Braking distance 8, 47 C Cable package, DKP-400 V1 15 Cable package, DKP-400 V2 17 Cable package, DKP-400 V3 18 Cable package, DKP-400 V4 19 Cable package, DKP-400 V5 21 Cables and hoses 38 CE mark 8, 46 Center of gravity 63 Cleaning work 55 Connecting cables 45 Control cable X76 - X86 39 Counterbalancing system 56 D Danger zone 8, 47 Declaration of conformity 46 Declaration of incorporation 45, 46 Decommissioning 56 Dimensions, transport 63 Disposal 56 Documentation, industrial robot 7 Drive unit 7 E EC declaration of conformity 46 Electromagnetic compatibility (EMC) 57 EMC Directive 46, 56 EMD 8 EN A1 57 EN EN A1 57 EN A1 57 EN ISO EN ISO EN ISO EN ISO EN ISO Energy supply system, DKP-400 V1 15 Energy supply system, DKP-400 V2 17 Energy supply system, DKP-400 V3 18 Energy supply system, DKP-400 V4 19 Energy supply system, DKP-400 V5 21 External axes 8, 45, 47 F Face plate 60 Faults 52 Foundation loads, DKP-400 V1 25 Foundation loads, DKP-400 V2 27 Foundation loads, DKP-400 V3 30 Foundation loads, DKP-400 V4 32 Foundation loads, DKP-400 V5 34 Function test 53 Functional ground 43 G General safety measures 51 Ground conductor, equipotential bonding 43 Grounding cable, 70 mm 41 H Handling equipment 63 Hazardous substances 56 Holder group 14 I Industrial robot 45 Intended use 46 Interface DKP-400 V1 16 Interface DKP-400 V2 17 Interface DKP-400 V5 22 Interface, DKP-400 V3 19 Interface, DKP-400 V4 20 Introduction 7 K KCP 47, 51 Keyboard, external 51 KP 8 KR C 8 KUKA Customer Support 65 Issued: Version: Spez DKP-400 V7 73 / 75

74 KUKA smartpad 8, 47 L Labeling 50 Liability 45 Linear unit 45 Low Voltage Directive 46 M Machine data 53 Machinery Directive 46, 56 Maintenance 55 Manipulator 8, 45, 47 Manual mode 54 Mechanical axis range limitation 49 Mechanical end stops 49 Mounting base 59 Mouse, external 51 O Operator 47, 48 Options 45 Overload 51 P Payloads, DKP-400 V1 25 Payloads, DKP-400 V2 27 Payloads, DKP-400 V3 30 Payloads, DKP-400 V4 32 Payloads, DKP-400 V5 34 Personnel 47 Planning 59 Plant integrator 47 Positioner 45 Pressure Equipment Directive 56, 57 Preventive maintenance work 55 Principal components 14 Product description 11 ProfiNet cable X62 - X72 41 Protective equipment, overview 49 Purpose 9 R RDC 8 Reaction distance 47 Recommissioning 52 Release device 8, 50 Repair 55 Robot controller 45 Robot system 8 Start-up 52 STOP 0 37, 47 STOP 1 47 STOP 2 47 Stop category 0 47 Stop category 1 47 Stop category 2 47 Stopping distance 47 Stopping distances 37 Storage 56 Support request 65 Swing frame 12 System integrator 46, 47, 48 T T1 47 T2 47 Teach pendant 45 Technical data 23 Technical data, DKP-400 V1 24 Technical data, DKP-400 V2 26 Technical data, DKP-400 V3 28 Technical data, DKP-400 V4 31 Technical data, DKP-400 V5 33 Technical data, overview 23 Terms used 7 Terms used, safety 47 Terms, used 7 Training 9 Transportation 52, 63 Turn-tilt table 45 U US1/US2 power supply X61 - X71 41 Use, contrary to intended use 45 Use, improper 45 Use, intended 9 User 47, 48 W Warnings 7 Working envelope 25, 27, 29, 32, 34 Working range limitation 49 Workspace 8, 47, 48 S Safety 45 Safety instructions 7 Safety of machinery 57 Safety zone 8, 47, 48 Safety, general 45 Service life 47 Service, KUKA Roboter GmbH 65 smartpad 8, 47, 51 Software / 75 Issued: Version: Spez DKP-400 V7

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