Positioner

KP5-V2S2V
Assembly Instructions

Issued: 16.04.2021
MA KP5-V2S2V V1
KUKA Deutschland GmbH
KP5-V2S2V

© Copyright 2021
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 soft-
ware 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 regu-
lar 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 KP5-V2S2V (PDF) en

PB16006

Book structure: MA KP5-V2S2V V1.1

BS14452

Version: MA KP5-V2S2V V1

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Contents

1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Positioning system documentation........................................................................ 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Terms used............................................................................................................ 8

2 Product description................................................................................. 11
2.1 Overview of the positioner.................................................................................... 11
2.2 Description of the positioner................................................................................. 11
2.3 Control and integration.......................................................................................... 13
2.4 Intended use and misuse...................................................................................... 14

3 Safety......................................................................................................... 17
3.1 General.................................................................................................................. 17
3.1.1 Disclaimer.............................................................................................................. 17
3.1.2 EC declaration of conformity and declaration of incorporation............................ 18
3.1.3 Terms in the “Safety” chapter............................................................................... 18
3.2 Personnel............................................................................................................... 20
3.3 Workspace, safety zone and danger zone........................................................... 21
3.4 Overview of protective equipment........................................................................ 21
3.4.1 Mechanical end stops........................................................................................... 22
3.4.2 Mechanical axis limitation (optional)..................................................................... 22
3.4.3 Options for moving the manipulator without drive energy................................... 22
3.4.4 Labeling on the industrial robot............................................................................ 23
3.5 Safety measures.................................................................................................... 23
3.5.1 General safety measures...................................................................................... 23
3.5.2 Transportation........................................................................................................ 25
3.5.3 Start-up and recommissioning.............................................................................. 25
3.5.4 Manual mode......................................................................................................... 27
3.5.5 Automatic mode..................................................................................................... 28
3.5.6 Maintenance and repair........................................................................................ 28
3.5.7 Decommissioning, storage and disposal.............................................................. 30

4 Technical data.......................................................................................... 31
4.1 Technical data, overview....................................................................................... 31
4.2 Technical data, KP5-V2S2V500 R600.................................................................. 32
4.2.1 Basic data, KP5-V2S2V500 R600........................................................................ 32
4.2.2 Axis data, KP5-V2S2V500 R600.......................................................................... 33
4.2.3 Payloads, KP5-V2S2V500 R600........................................................................... 36
4.2.4 Foundation loads, KP5-V2S2V500 R600............................................................. 36
4.3 Technical data, KP5-V2S2V500 R800.................................................................. 37
4.3.1 Basic data, KP5-V2S2V500 R800........................................................................ 37
4.3.2 Axis data, KP5-V2S2V500 R800.......................................................................... 39
4.3.3 Payloads, KP5-V2S2V500 R800........................................................................... 42
4.3.4 Foundation loads, KP5-V2S2V500 R800............................................................. 42
4.4 Technical data, KP5-V2S2V500 R1000................................................................ 43
4.4.1 Basic data, KP5-V2S2V500 R1000...................................................................... 43

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4.4.2 Axis data, KP5-V2S2V500 R1000........................................................................ 45

4.4.3 Payloads, KP5-V2S2V500 R1000......................................................................... 48
4.4.4 Foundation loads, KP5-V2S2V500 R1000........................................................... 48
4.5 Technical data, KP5-V2S2V1000 R600................................................................ 49
4.5.1 Basic data, KP5-V2S2V1000 R600...................................................................... 49
4.5.2 Axis data, KP5-V2S2V1000 R600........................................................................ 51
4.5.3 Payloads, KP5-V2S2V1000 R600......................................................................... 53
4.5.4 Foundation loads, KP5-V2S2V1000 R600........................................................... 54
4.6 Technical data, KP5-V2S2V1000 R800................................................................ 55
4.6.1 Basic data, KP5-V2S2V1000 R800...................................................................... 55
4.6.2 Axis data, KP5-V2S2V1000 R800........................................................................ 57
4.6.3 Payloads, KP5-V2S2V1000 R800......................................................................... 60
4.6.4 Foundation loads, KP5-V2S2V1000 R800........................................................... 60
4.7 Technical data, KP5-V2S2V1000 R1000.............................................................. 61
4.7.1 Basic data, KP5-V2S2V1000 R1000.................................................................... 61
4.7.2 Axis data, KP5-V2S2V1000 R1000...................................................................... 63
4.7.3 Payloads, KP5-V2S2V1000 R1000....................................................................... 66
4.7.4 Foundation loads, KP5-V2S2V1000 R1000......................................................... 66
4.8 Plates and labels................................................................................................... 67
4.9 REACH duty to communicate information acc. to Art. 33................................... 72
4.10 Stopping distances................................................................................................ 72

5 Planning.................................................................................................... 73
5.1 Information for planning........................................................................................ 73
5.2 Mounting base with centering............................................................................... 73
5.3 Machine frame mounting....................................................................................... 76
5.4 Dimensions of face plates..................................................................................... 78
5.5 Connecting cables and interfaces......................................................................... 79

6 Transportation.......................................................................................... 81
6.1 Transporting the positioner.................................................................................... 81

7 Start-up and recommissioning............................................................... 85

7.1 Starting up the positioner (mounting base).......................................................... 85
7.1.1 Installing the positioner with a mounting base..................................................... 87
7.1.2 Connecting the connecting cables........................................................................ 88
7.1.3 Machine data......................................................................................................... 89
7.1.4 Mastering the positioner........................................................................................ 89
7.1.5 Concluding work.................................................................................................... 92
7.2 Starting up the positioner (machine frame mounting).......................................... 92
7.2.1 Installing the positioner with machine frame mounting........................................ 94
7.2.2 Connecting the connecting cables........................................................................ 95
7.2.3 Machine data......................................................................................................... 95
7.2.4 Mastering the positioner........................................................................................ 96
7.2.5 Concluding work.................................................................................................... 98
7.3 Description of the connecting cables.................................................................... 98

8 Options...................................................................................................... 101
8.1 Anti-glare equipment (optional)............................................................................. 101
8.1.1 Putting the anti-glare equipment R600 into operation......................................... 105

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8.1.1.1 Fastening the anti-glare equipment...................................................................... 106

8.1.1.2 Concluding work.................................................................................................... 112
8.1.2 Putting the anti-glare equipment R800 into operation......................................... 112
8.1.2.1 Fastening the anti-glare equipment...................................................................... 113
8.1.2.2 Concluding work.................................................................................................... 120
8.1.3 Putting the anti-glare equipment R1000 into operation....................................... 120
8.1.3.1 Fastening the anti-glare equipment...................................................................... 121
8.1.3.2 Concluding work.................................................................................................... 129
8.1.4 Decommissioning................................................................................................... 129
8.1.4.1 Moving the positioner into its transport position.................................................. 130
8.1.4.2 Removing the anti-glare equipment...................................................................... 130
8.1.4.3 Concluding work.................................................................................................... 132
8.2 Weld current return, infinitely rotating (optional).................................................. 132
8.2.1 Exchanging the current collector.......................................................................... 136
8.2.1.1 Removing the current collector on the drive side................................................ 137
8.2.1.2 Installing the current collector on the drive side.................................................. 138
8.2.1.3 Concluding work.................................................................................................... 139
8.3 Position monitoring................................................................................................ 139

9 Appendix................................................................................................... 143
9.1 Tightening torques................................................................................................. 143
9.2 Auxiliary and operating materials used................................................................ 144
9.3 Applied standards and regulations....................................................................... 144

10 KUKA Service........................................................................................... 147

10.1 Requesting support............................................................................................... 147
10.2 KUKA Customer Support...................................................................................... 147

Index 149

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Introduction
1 Introduction

1.1 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 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 subsidia-
ries.

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 precau-
tions are taken.

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Introduction KP5-V2S2V

These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

This warning draws attention to procedures which serve to prevent or rem-

edy 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.

Term Description

Axis range Range of each axis, in degrees or millimeters, within which it 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

Danger zone The danger zone consists of the workspace and the stopping dis-
tances 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
Kinematic system that is controlled by the robot controller as an ex-
ternal axis.

KR C KUKA Robot Control

Robot controller

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

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Introduction
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).

Safety zone The safety zone is situated outside the danger zone.

smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:

• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
For robot controllers of the KR C5 series, only the model “smart-
PAD-2” is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to both models unless an explicit distinc-
tion is made.

PLC Programmable Logic Controller

Used in systems as a higher-level master module in the bus sys-
tem.

Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.

Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
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 Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. e.g. KUKA linear unit, turn-tilt table,
Posiflex

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Product description
2 Product description

2.1 Overview of the positioner

The KP5-V2S2V product family comprises the following positioners:

• KP5-V2S2V500 R600
• KP5-V2S2V500 R800
• KP5-V2S2V500 R1000
• KP5-V2S2V1000 R600
• KP5-V2S2V1000 R800
• KP5-V2S2V1000 R1000

Fig. 2-1: Overview of the positioner

2.2 Description of the positioner

Overview

The positioner has 5 axes, which are controlled via the robot controller. A
customer-specific or project-specific fixture is mounted by means of a me-
chanical 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 the document, the axes of the positioner are referred to as axis 1 (A1)
to axis 5 (A5). In the actual application, A1 to A5 might already be as-
signed to different system components.

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Fig. 2-2: Principal components

1 Face plate
2 Drive unit
3 Interface
4 Platform
5 Base frame
6 Rotating column
7 Link arm

Base frame

The base frame forms the basis of the positioner and houses the gear
unit with the motor. Fastened to the base frame is the platform, which
supports the rotating column. Also located on the base frame is the inter-
face for the motor and data cables and the energy supply system (option-
al). The platform is mounted on the base frame.

Rotating column

The rotating column houses the gear units and motors A2 and A4. The ro-
tational motion of axis 1 is performed by the rotating column. This is
screwed to the base frame via the gear unit of axis 1 and is driven by a
motor in the rotating column. The two link arms are also mounted in the
rotating column.

Link arm

The link arm is the assembly located between the rotating column and the
drive unit. It consists of a main plate, a flange plate and several other
plates.

Drive unit

The two drive units house the gear units and motors A3 and A5 as well
as the face plates. The workpiece fixtures are mounted on the face plates.
The face plates are electrically insulated.

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Product description
Electrical installations

The electrical installations include all the motor and data cables for the
motors of axes 1 to 5. The complete electrical installations consist of ca-
ble set A1 - A5.
The electrical installations also include holders and the RDC, which is fas-
tened in the rotating column.
All connections are implemented as connectors in order to enable the mo-
tors to be exchanged quickly and reliably. The electrical installations also
include a protective circuit. The ground conductors to the positioner are
connected to the base frame by means of ring cable lugs and setscrews.

Accessories

Only accessories authorized by KUKA Deutschland GmbH for this posi-

tioner may be used. All items of equipment must possess the appropriate
certification and EC declarations of conformity.

Options

The positioner can be fitted and operated with various options, e.g. an en-
ergy supply system. The option is described in separate documentation.
The following options are also available:
• Anti-glare equipment (>>> 8.1 "Anti-glare equipment (optional)"
Page 101)
• Weld current return cable (>>> 8.2 "Weld current return, infinitely rotat-
ing (optional)" Page 132)
• Position monitoring (>>> 8.3 "Position monitoring" Page 139)

2.3 Control and integration

Description

The drive units of the positioner are operated as external axes of the ro-
bot 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 kine-
matic 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 In-
tegrators.

An example of a mathematical coupling is depicted in the following dia-

gram.

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Fig. 2-3: 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.

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 re-
quires compliance with the operating and assembly instructions for the in-
dividual components, with particular reference to the maintenance specifi-
cations.

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.

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Product description
The positioner is an integral part of an overall system and may only be
operated in a CE-compliant system.

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Safety
3 Safety

3.1 General

• This “Safety” chapter refers to a mechanical component of an indus-

trial robot.
• If the mechanical component is used together with a KUKA robot
controller, the “Safety” chapter of the operating instructions or as-
sembly 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 con-
troller 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 accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial 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 ac-
cordance 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 au-
thorization of the manufacturer. Unauthorized modifications will result in
the loss of warranty and liability claims.
Additional components (tools, software, etc.), not supplied by the manufac-
turer, 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 in-
structions. These must also be observed.

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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 op-
eration 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 dec-
laration 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 incorpo-

ration in accordance with Annex II B of the Machinery Directive
2006/42/EC. The assembly instructions and a list of essential require-
ments 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 of each axis, in degrees or millimeters, within which it 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.

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Safety
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 dur-
ing storage.

Danger zone The danger zone consists of the workspace and the stopping dis-
tances 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 addi-
tional safe monitoring functions in addition to the standard safety
functions.
Example: SafeOperation

smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:

• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
For robot controllers of the KR C5 series, only the model “smart-
PAD-2” is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to both models unless an explicit distinc-
tion is made.

Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.

Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 in this document.

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Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking.

• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
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 The system integrator is responsible for safely integrating the indus-
(plant integrator) trial 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 Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. e.g. KUKA linear unit, turn-tilt table,
Posiflex

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, knowl-
edge of the relevant standards
• All persons working with the industrial robot must have read and un-
derstood 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 comply with his monitoring obligations.

• The user must carry out briefing at defined intervals.
• The user must comply with the regulations relating to personal protec-
tive equipment (PSA).

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 KP5-V2S2V

Safety
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 re-
quired after particular incidents or technical modifications.
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 sys-
tem 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 EC declaration of conformity
• Attaching 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. A work-

space must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone.
In the case of a stop, the manipulator and external axes (optional) are
braked and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). It must be safeguarded by
means of physical safeguards to prevent danger to persons or the risk of
material damage.

3.4 Overview of protective equipment

The protective equipment of the mechanical component may include:

• Mechanical end stops

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Safety KP5-V2S2V

• Mechanical axis limitation (optional)

• Release device (optional)
• Brake release device (optional)
• 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 ax-
es 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 mechani-
cal end stop or mechanical axis limitation, the manipulator can no
longer be operated safely. Death, injuries or damage to property may re-
sult.
• 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 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 me-
chanical 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 photo-
electric barriers, photoelectric curtains or obstacles on the system side.
There must be no shearing or crushing hazards at the loading and trans-
fer 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 are available for moving the manipulator without
drive energy after an accident or malfunction:

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Safety
• 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 ax-
es 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 in-
structions 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.
• 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 in-

structions 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 ac-
cordance with its intended use and only by safety-conscious persons. Op-
erator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial ro-
bot even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake de-
fect) 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

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 KP5-V2S2V

on their own, whether the payload is mounted or not. If this is not possi-
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 exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial 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.

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
The operator must ensure that decoupled KCPs/smartPADs are immedi-
ately removed from the system and stored out of sight and reach of per-
sonnel working on the industrial robot. This serves to prevent operation-
al and non-operational EMERGENCY STOP devices from becoming in-
terchanged.
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 fol-
lowing 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.

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Safety
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

The following tasks must be carried out in the case of faults in the indus-
trial 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.

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 in-
structions 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 in-
structions or assembly instructions of the robot controller.
Avoid vibrations and impacts during transportation in order to prevent
damage to the robot controller.

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 in-
structions 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 op-
erational, that they can be operated safely and that any damage is detec-
ted.
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.

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Safety KP5-V2S2V

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.

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 dam-
age 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 ambi-
ent temperature in order to avoid condensation.

Function test

The following tests must be carried out before start-up and recommission-
ing:
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.
WARNING
Danger to life and limb resulting from external forces
External forces, 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 ma-
nipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
‒ In the case of damage, the affected components must be ex-
changed.

• There are no foreign bodies or loose parts on the industrial robot.

• All required safety equipment is correctly installed and operational.

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Safety
• 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 suffi-
ciently rated and correctly connected.
• The connecting cables are correctly connected and the connectors are
locked.

3.5.4 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 opera-
tion. 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 uninten-
tionally.
• New or modified programs must always be tested first in Manual Re-
duced 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 safe-

guarded area.
If it is necessary for there to be several persons inside the safeguar-
ded 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 ve-
locity 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 ena-
bling 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.

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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.
• 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 EMER-
GENCY STOP has been triggered.

3.5.6 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 regula-
tions 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 addi-
tional 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 func-
tions 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 inju-
ries 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)

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Faulty components must be replaced using new components with the

Safety
same article numbers or equivalent components approved by the manu-
facturer for this purpose.
Cleaning and preventive maintenance work is to be carried out in accord-
ance with the operating instructions.

Robot controller

Even when the robot controller is switched off, parts connected to periph-
eral devices may still carry voltage. The external power sources must
therefore be switched off if work is to be carried out on the robot control-
ler.
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 com-
ponents 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.

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 there-
fore 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 ob-
served. As a rule, however, at least the maintenance intervals speci-
fied by KUKA must be observed. Shorter intervals are not permitted.
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 hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.

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• 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.

3.5.7 Decommissioning, storage and disposal

The industrial robot must be decommissioned, stored and disposed of in

accordance with the applicable national laws, regulations and standards.

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Technical data
4 Technical data

4.1 Technical data, overview

The technical data for the individual positioner types can be found in the
following sections:
Positioner Technical data
KP5-V2S2V500 R600 • Technical data
(>>> 4.2 "Technical data, KP5-V2S2V500 R600" Page 32)
• Plates and labels
(>>> 4.8 "Plates and labels" Page 67)
• Stopping distances and times
(>>> 4.10 "Stopping distances" Page 72)
KP5-V2S2V500 R800 • Technical data
(>>> 4.3 "Technical data, KP5-V2S2V500 R800" Page 37)
• Plates and labels
(>>> 4.8 "Plates and labels" Page 67)
• Stopping distances and times
(>>> 4.10 "Stopping distances" Page 72)
KP5-V2S2V500 • Technical data
R1000
(>>> 4.4 "Technical data, KP5-V2S2V500 R1000" Page 43)
• Plates and labels
(>>> 4.8 "Plates and labels" Page 67)
• Stopping distances and times
(>>> 4.10 "Stopping distances" Page 72)
KP5-V2S2V1000 • Technical data
R600
(>>> 4.5 "Technical data, KP5-V2S2V1000 R600" Page 49)
• Plates and labels
(>>> 4.8 "Plates and labels" Page 67)
• Stopping distances and times
(>>> 4.10 "Stopping distances" Page 72)
KP5-V2S2V1000 • Technical data
R800
(>>> 4.6 "Technical data, KP5-V2S2V1000 R800" Page 55)
• Plates and labels
(>>> 4.8 "Plates and labels" Page 67)
• Stopping distances and times
(>>> 4.10 "Stopping distances" Page 72)
KP5-V2S2V1000 • Technical data
R1000
(>>> 4.7 "Technical data, KP5-V2S2V1000 R1000" Page 61)
• Plates and labels
(>>> 4.8 "Plates and labels" Page 67)
• Stopping distances and times
(>>> 4.10 "Stopping distances" Page 72)

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4.2 Technical data, KP5-V2S2V500 R600

4.2.1 Basic data, KP5-V2S2V500 R600

Basic data

KP5-V2S2V500 R600
Number of axes 5
Weight approx. 2060 kg
Rated payload 500 kg
Protection rating (IEC 60529) IP67
Sound level < 78 dB (A)
Mounting position Floor
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009);
Cover: KUKA Industrial Orange
(RAL 2009)
Controller KR C4
Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Pose repeatability
A1 -
A2 -
A3 -
A4 -
A5 -

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
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)

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Technical data
Connecting cables

Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
X10.1 - XM10
X11.1 - XM11
Data cable X21.1 -X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)

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”.

4.2.2 Axis data, KP5-V2S2V500 R600

Axis data

Loading height 670 mm

Tool radius 600 mm
Motion range
A1 ±185 °
A2 ±185 °
A3 Infinite
A4 ±185 °
A5 Infinite
Motion range with energy supply system
A1 ±185 °
A2 ±185 °
A3 ±210 °
A4 ±185 °
A5 ±210 °
Turning time 180°
A1 3.4 s
A2 2.8 s
A3 1.6 s

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A4 2.8 s
A5 1.6 s
Turning time 360°
A1 6 s
A2 5.1 s
A3 2.8 s
A4 5.1 s
A5 2.8 s

NOTICE
If the positioner is moved through 360° at maximum speed, this may re-
sult in damage to the positioner. To prevent this, the speed should be
reduced.

Direction of rotation

The orientation of a rotational axis is defined on the motor side (drive):

• “+” clockwise
• “-” counterclockwise
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-1):

Fig. 4-1: Direction of rotation of the axes

Mastering positions

Mastering position
A1 -150 °
A2 90 °
A3 0 °
A4 90 °

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Technical data
A5 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.

Fig. 4-2: Working envelope, side view, KP5-V2S2V500 R600

Fig. 4-3: Working envelope, top view, KP5-V2S2V500 R600

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Technical data KP5-V2S2V

4.2.3 Payloads, KP5-V2S2V500 R600

Payloads

Maximum load torque

A1 -
A2 -
A3 981 Nm
A4 -
A5 981 Nm
Mass moment of inertia
A1 -
A2 220 kgm²
A3 140 kgm²
A4 220 kgm²
A5 140 kgm²

Nominal distance to load center of gravity

Rated payload 500 kg

Nominal distance to load center of gravity
Lx 700 mm
Ly 200 mm

Fig. 4-4: Load center of gravity

4.2.4 Foundation loads, KP5-V2S2V500 R600

Description

The specified forces and torques already include the payload and the iner-
tia force (weight) of the positioner.
Vertical force F(v)
F(v normal) 36000 N
F(v max) 37250 N
Horizontal force F(h)
F(h normal) 2000 N
F(h max) 3250 N

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Technical data
Tilting moment M(k)
M(k normal) 5600 Nm
M(k max) 7600 Nm
Torque about axis 1 M(r)
M(r normal) 9500 Nm
M(r max) 15000 Nm

Fig. 4-5: 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 founda-
tions 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, KP5-V2S2V500 R800

4.3.1 Basic data, KP5-V2S2V500 R800

Basic data

KP5-V2S2V500 R800
Number of axes 5
Weight approx. 2160 kg
Rated payload 500 kg
Protection rating (IEC 60529) IP67
Sound level < 78 dB (A)
Mounting position Floor

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Technical data KP5-V2S2V

KP5-V2S2V500 R800
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009);
Cover: KUKA Industrial Orange
(RAL 2009)
Controller KR C4
Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Pose repeatability
A1 -
A2 -
A3 -
A4 -
A5 -

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
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

Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
X10.1 - XM10
X11.1 - XM11
Data cable X21.1 -X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)

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”.

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 KP5-V2S2V

Technical data
4.3.2 Axis data, KP5-V2S2V500 R800

Axis data

Loading height 670 mm

Tool radius 800 mm
Motion range
A1 ±185 °
A2 ±185 °
A3 Infinite
A4 ±185 °
A5 Infinite
Motion range with energy supply system
A1 ±185 °
A2 ±185 °
A3 ±210 °
A4 ±185 °
A5 ±210 °
Turning time 180°
A1 3.7 s
A2 2.8 s
A3 1.6 s
A4 2.8 s
A5 1.6 s
Turning time 360°
A1 6.25 s
A2 5.1 s
A3 2.8 s
A4 5.1 s
A5 2.8 s

NOTICE
If the positioner is moved through 360° at maximum speed, this may re-
sult in damage to the positioner. To prevent this, the speed should be
reduced.

Direction of rotation

The orientation of a rotational axis is defined on the motor side (drive):

• “+” clockwise
• “-” counterclockwise
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-6):

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Technical data KP5-V2S2V

Fig. 4-6: Direction of rotation of the axes

Mastering positions

Mastering position
A1 -150 °
A2 90 °
A3 0 °
A4 90 °
A5 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.

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Technical data
Fig. 4-7: Working envelope, side view, KP5-V2S2V500 R800

Fig. 4-8: Working envelope, top view, KP5-V2S2V500 R800

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Technical data KP5-V2S2V

4.3.3 Payloads, KP5-V2S2V500 R800

Payloads

Maximum load torque

A1 -
A2 -
A3 736 Nm
A4 -
A5 736 Nm
Mass moment of inertia
A1 -
A2 250 kgm²
A3 200 kgm²
A4 250 kgm²
A5 200 kgm²

Nominal distance to load center of gravity

Rated payload 500 kg

Nominal distance to load center of gravity
Lx 700 mm
Ly 150 mm

Fig. 4-9: Load center of gravity

4.3.4 Foundation loads, KP5-V2S2V500 R800

Description

The specified forces and torques already include the payload and the iner-
tia force (weight) of the positioner.
Vertical force F(v)
F(v normal) 36750 N
F(v max) 38000 N
Horizontal force F(h)
F(h normal) 1750 N
F(h max) 3000 N

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 KP5-V2S2V

Technical data
Tilting moment M(k)
M(k normal) 5825 Nm
M(k max) 8575 Nm
Torque about axis 1 M(r)
M(r normal) 9500 Nm
M(r max) 15000 Nm

Fig. 4-10: 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 founda-
tions 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, KP5-V2S2V500 R1000

4.4.1 Basic data, KP5-V2S2V500 R1000

Basic data

KP5-V2S2V500 R1000
Number of axes 5
Weight approx. 2214 kg
Rated payload 500 kg
Protection rating (IEC 60529) IP67
Sound level < 78 dB (A)
Mounting position Floor

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Technical data KP5-V2S2V

KP5-V2S2V500 R1000
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009);
Cover: KUKA Industrial Orange
(RAL 2009)
Controller KR C4
Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Pose repeatability
A1 -
A2 -
A3 -
A4 -
A5 -

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
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

Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
X10.1 - XM10
X11.1 - XM11
Data cable X21.1 -X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)

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”.

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 KP5-V2S2V

Technical data
4.4.2 Axis data, KP5-V2S2V500 R1000

Axis data

Loading height 670 mm

Tool radius 1000 mm
Motion range
A1 ±185 °
A2 ±185 °
A3 Infinite
A4 ±185 °
A5 Infinite
Motion range with energy supply system
A1 ±185 °
A2 ±185 °
A3 ±210 °
A4 ±185 °
A5 ±210 °
Turning time 180°
A1 4 s
A2 2.8 s
A3 1.6 s
A4 2.8 s
A5 1.6 s
Turning time 360°
A1 6.5 s
A2 5.1 s
A3 2.8 s
A4 5.1 s
A5 2.8 s

NOTICE
If the positioner is moved through 360° at maximum speed, this may re-
sult in damage to the positioner. To prevent this, the speed should be
reduced.

Direction of rotation

The orientation of a rotational axis is defined on the motor side (drive):

• “+” clockwise
• “-” counterclockwise
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-11):

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Technical data KP5-V2S2V

Fig. 4-11: Direction of rotation of the axes

Mastering positions

Mastering position
A1 -150 °
A2 90 °
A3 0 °
A4 90 °
A5 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.

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 KP5-V2S2V

Technical data
Fig. 4-12: Working envelope, side view, KP5-V2S2V500 R1000

Fig. 4-13: Working envelope, top view, KP5-V2S2V500 R1000

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Technical data KP5-V2S2V

4.4.3 Payloads, KP5-V2S2V500 R1000

Payloads

Maximum load torque

A1 -
A2 -
A3 736 Nm
A4 -
A5 736 Nm
Mass moment of inertia
A1 -
A2 280 kgm²
A3 260 kgm²
A4 280 kgm²
A5 260 kgm²

Nominal distance to load center of gravity

Rated payload 500 kg

Nominal distance to load center of gravity
Lx 700 mm
Ly 150 mm

Fig. 4-14: Load center of gravity

4.4.4 Foundation loads, KP5-V2S2V500 R1000

Description

The specified forces and torques already include the payload and the iner-
tia force (weight) of the positioner.
Vertical force F(v)
F(v normal) 37500 N
F(v max) 39000 N
Horizontal force F(h)
F(h normal) 1500 N
F(h max) 3000 N
Tilting moment M(k)

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Technical data
M(k normal) 6625 Nm
M(k max) 10125 Nm
Torque about axis 1 M(r)
M(r normal) 9500 Nm
M(r max) 15000 Nm

Fig. 4-15: 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 founda-
tions 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, KP5-V2S2V1000 R600

4.5.1 Basic data, KP5-V2S2V1000 R600

Basic data

KP5-V2S2V1000 R600
Number of axes 5
Weight approx. 2060 kg
Rated payload 1000 kg
Protection rating (IEC 60529) IP67
Sound level < 78 dB (A)
Mounting position Floor
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009);
Cover: KUKA Industrial Orange
(RAL 2009)

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Technical data KP5-V2S2V

KP5-V2S2V1000 R600
Controller KR C4
Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Pose repeatability
A1 -
A2 -
A3 -
A4 -
A5 -

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
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

Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
X10.1 - XM10
X11.1 - XM11
Data cable X21.1 -X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)

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”.

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 KP5-V2S2V

Technical data
4.5.2 Axis data, KP5-V2S2V1000 R600

Axis data

Loading height 670 mm

Tool radius 600 mm
Motion range
A1 ±185 °
A2 ±185 °
A3 Infinite
A4 ±185 °
A5 Infinite
Motion range with energy supply system
A1 ±185 °
A2 ±185 °
A3 ±210 °
A4 ±185 °
A5 ±210 °
Turning time 180°
A1 3.4 s
A2 3 s
A3 2 s
A4 3 s
A5 2 s
Turning time 360°
A1 6 s
A2 5.5 s
A3 3.2 s
A4 5.5 s
A5 3.2 s

NOTICE
If the positioner is moved through 360° at maximum speed, this may re-
sult in damage to the positioner. To prevent this, the speed should be
reduced.

Direction of rotation

The orientation of a rotational axis is defined on the motor side (drive):

• “+” clockwise
• “-” counterclockwise
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-16):

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Technical data KP5-V2S2V

Fig. 4-16: Direction of rotation of the axes

Mastering positions

Mastering position
A1 -150 °
A2 90 °
A3 0 °
A4 90 °
A5 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.

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 KP5-V2S2V

Technical data
Fig. 4-17: Working envelope, side view, KP5-V2S2V1000 R600

Fig. 4-18: Working envelope, top view, KP5-V2S2V1000 R600

4.5.3 Payloads, KP5-V2S2V1000 R600

Payloads

Maximum load torque

A1 -

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Technical data KP5-V2S2V

A2 -
A3 1472 Nm
A4 -
A5 1472 Nm
Mass moment of inertia
A1 -
A2 200 kgm²
A3 220 kgm²
A4 200 kgm²
A5 220 kgm²

Nominal distance to load center of gravity

Rated payload 1000 kg

Nominal distance to load center of gravity
Lx 350 mm
Ly 150 mm
The minimum nominal distance to load center of gravity Lx must not be
less than 100 mm.

Fig. 4-19: Load center of gravity

4.5.4 Foundation loads, KP5-V2S2V1000 R600

Description

The specified forces and torques already include the payload and the iner-
tia force (weight) of the positioner.
Vertical force F(v)
F(v normal) 46000 N
F(v max) 47500 N
Horizontal force F(h)
F(h normal) 2000 N
F(h max) 3500 N
Tilting moment M(k)
M(k normal) 7550 Nm
M(k max) 13500 Nm

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 KP5-V2S2V

Technical data
Torque about axis 1 M(r)
M(r normal) 9500 Nm
M(r max) 15000 Nm

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 founda-
tions 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, KP5-V2S2V1000 R800

4.6.1 Basic data, KP5-V2S2V1000 R800

Basic data

KP5-V2S2V1000 R800
Number of axes 5
Weight approx. 2160 kg
Rated payload 1000 kg
Protection rating (IEC 60529) IP67
Sound level < 78 dB (A)
Mounting position Floor
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009);
Cover: KUKA Industrial Orange
(RAL 2009)

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Technical data KP5-V2S2V

KP5-V2S2V1000 R800
Controller KR C4
Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Pose repeatability
A1 -
A2 -
A3 -
A4 -
A5 -

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
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

Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
X10.1 - XM10
X11.1 - XM11
Data cable X21.1 -X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)

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”.

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 KP5-V2S2V

Technical data
4.6.2 Axis data, KP5-V2S2V1000 R800

Axis data

Loading height 670 mm

Tool radius 800 mm
Motion range
A1 ±185 °
A2 ±185 °
A3 Infinite
A4 ±185 °
A5 Infinite
Motion range with energy supply system
A1 ±185 °
A2 ±185 °
A3 ±210 °
A4 ±185 °
A5 ±210 °
Turning time 180°
A1 3.7 s
A2 3 s
A3 2 s
A4 3 s
A5 2 s
Turning time 360°
A1 6.25 s
A2 5.5 s
A3 3.2 s
A4 5.5 s
A5 3.2 s

NOTICE
If the positioner is moved through 360° at maximum speed, this may re-
sult in damage to the positioner. To prevent this, the speed should be
reduced.

Direction of rotation

The orientation of a rotational axis is defined on the motor side (drive):

• “+” clockwise
• “-” counterclockwise
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-21):

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Technical data KP5-V2S2V

Fig. 4-21: Direction of rotation of the axes

Mastering positions

Mastering position
A1 -150 °
A2 90 °
A3 0 °
A4 90 °
A5 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.

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 KP5-V2S2V

Technical data
Fig. 4-22: Working envelope, side view, KP5-V2S2V1000 R800

Fig. 4-23: Working envelope, top view, KP5-V2S2V1000 R800

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Technical data KP5-V2S2V

4.6.3 Payloads, KP5-V2S2V1000 R800

Payloads

Maximum load torque

A1 -
A2 -
A3 1472 Nm
A4 -
A5 1472 Nm
Mass moment of inertia
A1 -
A2 260 kgm²
A3 320 kgm²
A4 260 kgm²
A5 320 kgm²

Nominal distance to load center of gravity

Rated payload 1000 kg

Nominal distance to load center of gravity
Lx 350 mm
Ly 150 mm
The minimum nominal distance to load center of gravity Lx must not be
less than 100 mm.

Fig. 4-24: Load center of gravity

4.6.4 Foundation loads, KP5-V2S2V1000 R800

Description

The specified forces and torques already include the payload and the iner-
tia force (weight) of the positioner.
Vertical force F(v)
F(v normal) 46750 N
F(v max) 48500 N
Horizontal force F(h)

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 KP5-V2S2V

Technical data
F(h normal) 1750 N
F(h max) 3500 N
Tilting moment M(k)
M(k normal) 8150 Nm
M(k max) 15500 Nm
Torque about axis 1 M(r)
M(r normal) 9500 Nm
M(r max) 15000 Nm

Fig. 4-25: 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 founda-
tions 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, KP5-V2S2V1000 R1000

4.7.1 Basic data, KP5-V2S2V1000 R1000

Basic data

KP5-V2S2V1000 R1000
Number of axes 5
Weight approx. 2214 kg
Rated payload 1000 kg
Protection rating (IEC 60529) IP67
Sound level < 78 dB (A)
Mounting position Floor

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Technical data KP5-V2S2V

KP5-V2S2V1000 R1000
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009);
Cover: KUKA Industrial Orange
(RAL 2009)
Controller KR C4
Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Pose repeatability
A1 -
A2 -
A3 -
A4 -
A5 -

Ambient conditions

Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
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

Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
X10.1 - XM10
X11.1 - XM11
Data cable X21.1 -X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)

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”.

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 KP5-V2S2V

Technical data
4.7.2 Axis data, KP5-V2S2V1000 R1000

Axis data

Loading height 670 mm

Tool radius 1000 mm
Motion range
A1 ±185 °
A2 ±185 °
A3 Infinite
A4 ±185 °
A5 Infinite
Motion range with energy supply system
A1 ±185 °
A2 ±185 °
A3 ±210 °
A4 ±185 °
A5 ±210 °
Turning time 180°
A1 4 s
A2 3 s
A3 2 s
A4 3 s
A5 2 s
Turning time 360°
A1 6.5 s
A2 5.5 s
A3 3.2 s
A4 5.5 s
A5 3.2 s

NOTICE
If the positioner is moved through 360° at maximum speed, this may re-
sult in damage to the positioner. To prevent this, the speed should be
reduced.

Direction of rotation

The orientation of a rotational axis is defined on the motor side (drive):

• “+” clockwise
• “-” counterclockwise
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-26):

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Technical data KP5-V2S2V

Fig. 4-26: Direction of rotation of the axes

Mastering positions

Mastering position
A1 -150 °
A2 90 °
A3 0 °
A4 90 °
A5 0 °

Working envelope

The following diagrams show the shape and size of the working envelope
for these variants of this product family.

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 KP5-V2S2V

Technical data
Fig. 4-27: Working envelope, side view, KP5-V2S2V1000 R1000

Fig. 4-28: Working envelope, top view, KP5-V2S2V1000 R1000

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Technical data KP5-V2S2V

4.7.3 Payloads, KP5-V2S2V1000 R1000

Payloads

Maximum load torque

A1 -
A2 -
A3 981 Nm
A4 -
A5 981 Nm
Mass moment of inertia
A1 -
A2 320 kgm²
A3 420 kgm²
A4 320 kgm²
A5 420 kgm²

Nominal distance to load center of gravity

Rated payload 1000 kg

Nominal distance to load center of gravity
Lx 350 mm
Ly 100 mm
The minimum nominal distance to load center of gravity Lx must not be
less than 100 mm.

Fig. 4-29: Load center of gravity

4.7.4 Foundation loads, KP5-V2S2V1000 R1000

Description

The specified forces and torques already include the payload and the iner-
tia force (weight) of the positioner.
Vertical force F(v)
F(v normal) 47500 N
F(v max) 49000 N
Horizontal force F(h)

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Technical data
F(h normal) 1500 N
F(h max) 3000 N
Tilting moment M(k)
M(k normal) 8850 Nm
M(k max) 17000 Nm
Torque about axis 1 M(r)
M(r normal) 9500 Nm
M(r max) 15000 Nm

Fig. 4-30: 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 founda-
tions 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 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.

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Technical data KP5-V2S2V

Fig. 4-31: Location of plates and labels

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Technical data
Fig. 4-32: Location of plates and labels if using an energy supply
system (optional)

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Technical data KP5-V2S2V

Item Description
1

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 crush-
ing!
2

Do not slacken screwed connection

Do not slacken screwed connection! Observe safety instructions
and assembly instructions!
3

Work on the positioner

Before start-up, transportation or maintenance, read and follow
the assembly and operating instructions.
4

Danger zone
Entering the danger zone of the positioner is prohibited if the
positioner is in operation or ready for operation. Risk of injury!
5

High voltage
Any improper handling can lead to contact with current-carrying
components. Electric shock hazard!

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Technical data
Item 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

Identification plate
Content according to Machinery Directive.
The QR code contains a link to product information in KUKA
Xpert.
8

Direction of translation/rotation
The label shows the plus and minus directions of the corre-
sponding translational/rotational axis.
9

Axis designation
10

Axis designation
11

Axis designation

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Technical data KP5-V2S2V

4.9 REACH duty to communicate information acc. to Art. 33

As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment 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.

4.10 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 nec-
essary under the real conditions of the actual positioner application.
• Measuring technique
The stopping distances were measured using the robot-internal meas-
uring technique.
• The wear on the brakes varies depending on the operating mode, ro-
bot application and the number of STOP 0 stops triggered. It is there-
fore 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/A3
KP5-V2S2V500 R600 - -
KP5-V2S2V500 R800 - -
KP5-V2S2V500 R1000 - -
KP5-V2S2V1000 R600 - -
KP5-V2S2V1000 R800 - -
KP5-V2S2V1000 R1000 - -

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Planning
5 Planning

5.1 Information for planning

In the planning and design phase, care must be taken regarding the func-
tions or applications to be executed by the kinematic system. The follow-
ing conditions can lead to premature wear. They necessitate shorter main-
tenance 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 environ-
ments
• 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 mo-
tions
• External forces (process forces) acting on the robot
If one or more of these conditions are to apply during operation of the kin-
ematic system, KUKA Deutschland GmbH must be consulted.
If the positioner reaches its corresponding operation limit or if it is operat-
ed 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 with centering

Description

The mounting base with centering is used when the kinematic system is
fastened to the floor, i.e. directly on a concrete foundation.
The mounting base with centering consists of:
• Bedplates
• 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.
There must be no layers of insulation or screed between the bedplates
and the concrete foundation.
The minimum dimensions must be observed.

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Planning KP5-V2S2V

Fig. 5-1: Mounting base

1 Bedplate (4x)
2 Locating pin, cylindrical
3 M24x65-8.8-A2K hexagon screw with conical spring washer (8x)
4 Resin-bonded anchor (12x)
5 M20 tapped hole for leveling screws (4x)
6 Locating pin, flat-sided

Grade of concrete for foundations

When producing foundations from concrete, observe the load-bearing ca-

pacity 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 DIN EN 206-1:2001/DIN 1045-2:2008

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 ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.

Dimensioned drawing

The following illustration (>>> Fig. 5-2) provides all the necessary informa-
tion on the mounting base, together with the required foundation data. The
specified foundation dimensions refer to the safe transmission of the foun-
dation loads into the foundation and not to the stability of the foundation.

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Planning
Fig. 5-2: Mounting base, dimensioned drawing

1 Concrete foundation
2 M24x65-8.8-A2K hexagon bolt (8x)
3 Locating pin, cylindrical
4 Locating pin, flat-sided
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration.
NOTICE
The dimensions specified for the distance to the edge are valid for non-
reinforced or normally reinforced concrete without verification of
concrete edge failure. For safety against concrete edge failure in ac-
cordance with ETAG 001 Annex C, the concrete foundation must be
provided with an appropriate edge reinforcement.

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Planning KP5-V2S2V

Fig. 5-3: Foundation cross-section

1 Locating pin 3 Bedplate

2 Hexagon bolt with lock wash- 4 Concrete foundation
er

A: min. distance to edge B: min. concrete thickness

360 mm 180 mm
340 mm 200 mm
300 mm 250 mm

5.3 Machine frame mounting

Description

The “machine frame mounting” assembly is used when the kinematic sys-
tem is fastened to a steel structure, a booster frame (pedestal) or a KUKA
linear unit. It must be ensured that the substructure is able to withstand
safely the forces occurring during operation (foundation loads). The follow-
ing diagram contains all the necessary information that must be observed
when preparing the mounting surface (>>> Fig. 5-4).
The machine frame mounting assembly consists of:
• Locating pins
• Hexagon bolts with conical spring washers

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Planning
Fig. 5-4: Machine frame mounting

Dimensioned drawing

The following illustration (>>> Fig. 5-5) provides all the necessary informa-
tion on machine frame mounting, together with the required foundation da-
ta.

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Planning KP5-V2S2V

Fig. 5-5: Machine frame mounting, dimensioned drawing

5.4 Dimensions of face plates

The dimensions of the face plates are specified in the following diagram
(>>> Fig. 5-6).

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Planning
Fig. 5-6: Dimensions, face plate

5.5 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. They
are connected on the positioner side with connectors at interface A1. Con-
nection to the controller is always the same, irrespective of the controller
variant.
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 ca-
bles may be combined with each other.
For the connecting cables, an additional ground conductor is always re-
quired to provide a low-resistance connection between the positioner and
the control cabinet in accordance with DIN EN 60204. The ground con-
ductor is connected via ring cable lugs. The threaded bolts for connecting
the two ground conductors are located on the base frame of the position-
er.
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 com-
patibility (EMC).

Interface A1

Interface A1 is located at the rear of the base frame.

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Planning KP5-V2S2V

Fig. 5-7: Interface A1

1 Motor cable XM11

2 Data cable to RDC X31.1
3 Motor cable XM7
4 Motor cable XM8
5 Motor cable XM10
6 Data cable from RDC X21.1 to cascadable RDC
7 Motor cable XM9

Interface for energy supply system

The robot can be equipped with an energy supply system between A1

and A3/A5. The interface A1 required for this is located at the rear of the
base frame of the positioner. Depending on the application, the interfaces
differ in design and scope. They can be equipped, for example, with con-
nections for cables and hoses. Detailed information on the connector pin
allocation, threaded unions, etc. is given in separate documentation.

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Transportation
6 Transportation

6.1 Transporting the positioner

It must be ensured that the positioner is stable while it is being transpor-

ted. The positioner must remain in its transport position until it has been
fastened in position. 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 adhesive on contact sur-
faces.
The center of gravity must be taken into account during transportation.
Remove any disruptive add-on parts (e.g. energy supply system) before
transportation.

Transport position

The positioner must be in the transport position before it can be transpor-

ted. The transport position is the same for all positioners of this model.
The positioner is in the transport position when the axes are in the follow-
ing positions:

Fig. 6-1: Transport position

Transport dimensions

The transport dimensions for the positioner can be noted from the follow-
ing figure. The position of the center of gravity and the weight vary ac-
cording to the specific configuration. The specified dimensions refer to the
positioner without equipment.

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Transportation KP5-V2S2V

Fig. 6-2: Transport dimensions

1 Positioner 2 Fork slots

Transport dimensions
Robot A
KP5-V2S2V500 R600 3030
KP5-V2S2V500 R800 3830
KP5-V2S2V500 R1000 4630
KP5-V2S2V1000 R600 3030
KP5-V2S2V1000 R800 3830
KP5-V2S2V1000 R1000 4630

Transportation

The positioner can be transported by means of a crane or using a fork lift

truck and fork slots (optional).
WARNING
Use of unsuitable handling equipment may result in damage to the posi-
tioner or injury to persons. Only use authorized handling equipment with
a sufficient load-bearing capacity. The positioner may only be transpor-
ted in the manner specified here.

Transportation by fork lift truck

For transport by fork lift truck (>>> Fig. 6-3), four fork slots are mounted
on the base frame. The positioner must be in the transport position. The
positioner can be picked up by the fork lift truck from the front and from
the rear. The base frame must not be damaged when inserting the forks
into the fork slots.

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Transportation
NOTICE
Damage to property due to overloading of the fork slots
Overloading the fork slots during transportation can cause damage to
property.
• Avoid overloading the fork slots through undue inward or outward
movement of hydraulically adjustable forks of the fork lift truck.

Fig. 6-3: Transportation by fork lift truck

Transportation using lifting tackle

To install the positioner on the floor, it can be transported using a crane

and lifting tackle (not included in scope of supply) (>>> Fig. 6-4). For this,
it must be in the transport position. The lifting tackle is attached via 4 M16
swivel eyebolts that are screwed into the rotating column. All ropes must
be long enough and must be routed in such a way that the positioner is
not damaged. Installed tools and pieces of equipment can cause undesir-
able shifts in the center of gravity. These must therefore be removed if
necessary.
The swivel eyebolts must be removed after 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 tip-
ping. Additional safeguarding measures must be taken. It is forbidden to
pick up the positioner in any other way using a crane.

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Transportation KP5-V2S2V

Fig. 6-4: Transportation using lifting tackle

1 Crane
2 Lifting tackle (not included in scope of supply)
3 M16 swivel eyebolt

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Start-up and recommissioning

7 Start-up and recommissioning
The procedure for start-up and recommissioning comprises the following
steps:
Description Information
Installation with mounting Start-up (mounting base)
base
(>>> 7.1 "Starting up the positioner (mounting base)"
Page 85)
Installation with machine Start-up (machine frame mounting)
frame mounting
(>>> 7.2 "Starting up the positioner (machine frame mount-
ing)" Page 92)

7.1 Starting up the positioner (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 / bed-
plates and resin-bonded anchors.
If the surface of the concrete foundation is not sufficiently smooth and
even, the differences must be evened out with a suitable leveling com-
pound.
When using a Dynamic Set and resin-bonded anchors, use only compo-
nents 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.

Equipment

The following equipment is required:

Designation Article number
Lifting tackle/rope sling with sufficient -
load-bearing capacity
Crane with sufficient load-bearing capaci- -
ty
Fork lift truck with a sufficient load-bear- -
ing capacity
Drill with a ø 18 mm bit -
Setting tool approved by the anchor -
manufacturer
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 to 20 Nm
Torque wrench -
min. 400 to 700 Nm

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Start-up and recommissioning KP5-V2S2V

Material

The following material is required:

Designation Article number Quantity
Mounting base set S780 0000-327-118 1

Tightening torques

The tightening torques can be found under: (>>> 9.1 "Tightening torques"
Page 143)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification 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 installation site is accessible with a fork lift truck.

• 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 posi-
tioner 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 opera-
tion.

WARNING
Use of unsuitable handling equipment may result in damage to the posi-
tioner or injury to persons. Only use authorized handling equipment with
a sufficient load-bearing capacity. The positioner may only be transpor-
ted in the manner specified here.

WARNING
The positioner may tip over during transportation. Risk of personal injury
and damage to property
If the positioner is transported by fork lift truck, the forks must be inser-
ted in the fork slots. It is forbidden to pick up the robot in any other way
using a fork lift truck or lifting tackle!

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Start-up and recommissioning

7.1.1 Installing the positioner with a mounting base

Procedure

1. Clean the concrete foundation.

2. Screw 2 locating pins into the bedplates and check that they are fitted
securely (>>> Fig. 7-1).
3. Lift the positioner with a fork lift truck or crane and move it to the in-
stallation site.
4. Clean the lower mounting surface on the positioner.
5. Fasten the 4 bedplates to the positioner using 2 M24x65-8.8 hexagon
bolts and conical spring washers for each one. Ensure that an entirely
vertical position is maintained in order to prevent damage to the locat-
ing pins.
6. Tighten 8 M24x65-8.8 hexagon bolts with torque wrench. Increase the
tightening torque to the specified value in several stages.

Fig. 7-1: Mounting base

1 Bedplate (4x)
2 Locating pin, cylindrical
3 M24x65-8.8-A2K hexagon screw with conical spring washer (8x)
4 Resin-bonded anchor (12x)
5 M20 tapped hole for leveling screws (4x)
6 Locating pin, flat-sided

7. Determine the position of the positioner on the foundation in relation to

the working envelope.
8. Set the positioner down on the foundation in its installation position.
9. Check the surface of the concrete foundation against the specified val-
ue:
• If the surface is sufficiently smooth and even, continue with step
15.
• If the surface is not sufficiently smooth and even, continue with
step 10.
If the evenness of the foundation is outside the specified tolerances,
this can cause strain or result in loosening of the mounting base.
10. Lift the positioner with a fork lift truck.

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11. Apply sufficient leveling compound to the underside of the bedplates

(toothed spatula).
The area under the hexagon bolt for fastening the positioner must be
kept free from leveling compound.
12. Set down the positioner and align horizontally with leveling screws if
necessary.
13. Remove excess leveling compound. The maximum height of the level-
ing compound must not be exceeded. Observe the manufacturer’s
specifications.
14. Allow the leveling compound to set in accordance with the manufactur-
er's instructions.
15. Drill 12 anchor holes in accordance with the manufacturer’s specifica-
tions 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 positioner

1 Bedplate (4x)
2 M24x65-8.8-A2K hexagon bolt with conical spring washer (8x)
3 Locating pin

7.1.2 Connecting the connecting cables

Procedure

1. Fasten the ground conductor between the robot controller and the po-
sitioner to the ground conductor connection with 1 M8 hexagon nut in-
cluding conical spring washer; tightening torque MA= 23.0 Nm.
2. Connect data cable X31.1.
3. Connect motor cables XM7.1, XM8.1, XM9.1, XM10.1 and XM11.1.
When connecting the motor cable connectors, it must be ensured that
the connectors on the controller and on the robot are locked correctly.
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.
4. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.

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Start-up and recommissioning

Further information is contained in the operating and assembly in-
structions of the robot controller.

Fig. 7-3: Connecting the connecting cables (example)

1 Ground conductor (optional)

2 Connection XM11, motor cable XM11.1 (A5)
3 Data cable X21.1 (cascadable RDC)
4 Data cable X31.1
5 Connection XM7, motor cable XM7.1 (A1)
6 Connection XM8, motor cable XM8.1 (A2)
7 Connection XM10, motor cable XM10.1 (A4)
8 Connection XM9, motor cable XM9.1 (A3)

7.1.3 Machine data

Description

In the case of commissioning with the KR C4, the positioner must be con-
figured 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.

Further information about WorkVisual is contained in the WorkVisual

documentation and about configuration of the machine data in the oper-
ating and assembly instructions Configuration of Kinematic Systems.

Further information is contained in the operating and programming in-

structions for the corresponding KUKA System Software (KSS).

7.1.4 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

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the encoder value for each axis is saved. In this way, the mechanical zero
Start-up and recommissioning

position and the electronic zero position are made to coincide.

When mastering positioners, the axes must be mastered in ascending or-
der.

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 in-

structions.

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. 7-4: Mastering run

1 Pre-mastering position 5 Gauge cartridge

2 Motion direction of axis 6 Probe pin
3 Mechanical zero position 7 Reference notch
4 EMD

Position of the gauge cartridges

The EMD is fastened to the corresponding gauge cartridge. The following

figure (>>> Fig. 7-5) shows the positions of the gauge cartridges.

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Start-up and recommissioning

Fig. 7-5: Position of the gauge cartridges

1 Gauge cartridge A5 4 Gauge cartridge A3

2 Gauge cartridge A1 5 Gauge cartridge A2
3 Gauge cartridge A4

Mechanical zero position

The mechanical zero position of A1 is given when A1 has moved 150° in

the minus direction (>>> Fig. 7-6).

Fig. 7-6: Mechanical zero position, A1

The mechanical zero position of A2 and A4 is given when these axes

have each moved 90° in the plus direction (>>> Fig. 7-7).

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Fig. 7-7: Mechanical zero position, A2 and A4

1 Gauge cartridge A2/A4

2 Link arm A2/A4

7.1.5 Concluding work

The following concluding work must be carried out:

• 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 in-
structions for the KUKA System Software (KSS).

7.2 Starting up the positioner (machine frame mounting)

Description

The following sections describe the installation of the positioner using ma-
chine frame mounting.
8 Allen screws with lock washers are used for fastening it to a machine
frame. A cylindrical pin and a flat-sided pin are provided to ensure correct
positioning.
The machine frame mounting is used for installing positioners on a mount-
ing surface prepared by the customer or on an adapter plate (optional).
NOTICE
If a fixture is used, the positioner must be secured in such a way that
slipping is impossible. Only approved fixtures with an adequate carrying
capacity may be used. Damage to property may otherwise result.

The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.
Move the positioner into its transport position each time it is transported. It
must be ensured that the robot is stable while it is being transported. The
positioner must remain in its transport position until it has been fastened
to the foundation. 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 corrosion or adhesive on con-
tact surfaces.

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Equipment

The following equipment is required:

Designation Article number
Fork lift truck with a sufficient load-bear- -
ing capacity
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 to 20 Nm
Torque wrench -
min. 400 to 700 Nm

Material

The following material is required:

Designation Article number Quantity
Machine frame mounting 0000-310-641 1

Tightening torques

The tightening torques can be found under: (>>> 9.1 "Tightening torques"
Page 143)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification 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 installation site is accessible with a fork lift truck.

• The positioner is in the transport position.
• The substructure has been checked for sufficient safety.
• The mounting surface has been prepared.
• Any tools or other system components which would hinder the work
have been removed.
• The connecting cables and ground conductors are routed to the posi-
tioner 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 opera-
tion.

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WARNING
Use of unsuitable handling equipment may result in damage to the posi-
tioner or injury to persons. Only use authorized handling equipment with
a sufficient load-bearing capacity. The positioner may only be transpor-
ted in the manner specified here.

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 tip-
ping. Additional safeguarding measures must be taken. It is forbidden to
pick up the positioner in any other way using a crane.

7.2.1 Installing the positioner with machine frame mounting

Procedure

1. Clean the mounting surface.

2. Check the hole pattern on the mounting surface.
3. Screw 2 locating pins into the mounting surface and check that they
are fitted securely.
4. Lift the positioner with the fork lift truck and move it to the installation
site.
5. Clean the lower mounting surface on the positioner.
6. Lower the positioner vertically onto the installation surface. Ensure that
an entirely vertical position is maintained in order to prevent damage
to the locating pins.
7. Insert 8 M24x65-8.8 Allen screws with conical spring washers.
8. Tighten 8 M24x65-8.8 Allen screws with a torque wrench in diagonally
opposite sequence. Increase the tightening torque to the specified val-
ue in several stages.
9. For each fork slot, unscrew 2 M16x50-8.8 Allen screws with conical
spring washers and remove the 4 fork slots.

Fig. 7-8: Machine frame mounting

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7.2.2 Connecting the connecting cables

Procedure

1. Fasten the ground conductor between the robot controller and the po-
sitioner to the ground conductor connection with 1 M8 hexagon nut in-
cluding conical spring washer; tightening torque MA= 23.0 Nm.
2. Connect data cable X31.1.
3. Connect motor cables XM7.1, XM8.1, XM9.1, XM10.1 and XM11.1.
When connecting the motor cable connectors, it must be ensured that
the connectors on the controller and on the robot are locked correctly.
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.
4. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.
Further information is contained in the operating and assembly in-
structions of the robot controller.

Fig. 7-9: Connecting the connecting cables (example)

1 Ground conductor (optional)

2 Connection XM11, motor cable XM11.1 (A5)
3 Data cable X21.1 (cascadable RDC)
4 Data cable X31.1
5 Connection XM7, motor cable XM7.1 (A1)
6 Connection XM8, motor cable XM8.1 (A2)
7 Connection XM10, motor cable XM10.1 (A4)
8 Connection XM9, motor cable XM9.1 (A3)

7.2.3 Machine data

Description

In the case of commissioning with the KR C4, the positioner must be con-
figured with the aid of WorkVisual.

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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 oper-
ating and assembly instructions Configuration of Kinematic Systems.

Further information is contained in the operating and programming in-

structions for the corresponding KUKA System Software (KSS).

7.2.4 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 or-
der.

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 in-

structions.

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 “-”.

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Fig. 7-10: Mastering run

1 Pre-mastering position 5 Gauge cartridge

2 Motion direction of axis 6 Probe pin
3 Mechanical zero position 7 Reference notch
4 EMD

Position of the gauge cartridges

The EMD is fastened to the corresponding gauge cartridge. The following

figure (>>> Fig. 7-11) shows the positions of the gauge cartridges.

Fig. 7-11: Position of the gauge cartridges

1 Gauge cartridge A5 4 Gauge cartridge A3

2 Gauge cartridge A1 5 Gauge cartridge A2
3 Gauge cartridge A4

Mechanical zero position

The mechanical zero position of A1 is given when A1 has moved 150° in

the minus direction (>>> Fig. 7-12).

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Fig. 7-12: Mechanical zero position, A1

The mechanical zero position of A2 and A4 is given when these axes

have each moved 90° in the plus direction (>>> Fig. 7-13).

Fig. 7-13: Mechanical zero position, A2 and A4

1 Gauge cartridge A2/A4

2 Link arm A2/A4

7.2.5 Concluding work

The following concluding work must be carried out:

• 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 in-
structions for the KUKA System Software (KSS).

7.3 Description of the connecting cables

Configuration

The connecting cables are used to transfer power and data between the
robot controller and the positioner.
The connecting cables comprise:
• Motor cable

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• Data cable
• Ground conductor/equipotential bonding (optional)

Interface

Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
X10.1 - XM10
X11.1 - XM11
Data cable X21.1 - X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)

Standard connecting cable

Fig. 7-14: Connecting cables, overview

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8 Options

8.1 Anti-glare equipment (optional)

Description

The anti-glare equipment is fastened to the positioner and serves as a

safeguard during welding work.

Fig. 8-1: Anti-glare equipment, components

1 Upper bracket (2x)

2 Reinforcement (2x)
3 Upper bracket, center (2x)
4 Cover plate (2x)
5 Element, center
6 Upright element R600/R800/R1000 (2x)
7 Upright element (2x)
8 Upright element, center (x)

Basic data

Name Article number Weight

Reach of R600: 0000-368-942 approx.
Glare shield R600 122.1 kg
Reach of R800: 0000-368-943 approx.
Glare shield R800 149.2 kg
Reach of R1000: 0000-368-944 approx.
Glare shield R1000 171.7 kg

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Further information about the ambient conditions is contained in the as-

sembly instructions for the positioner and robot controller.

Dimensions of anti-glare equipment, R600

The following figure (>>> Fig. 8-2) shows the dimensions of the anti-glare
equipment.

Fig. 8-2: Anti-glare equipment, dimensions, R600

Dimensions of anti-glare equipment, R800

The following figure (>>> Fig. 8-3) shows the dimensions of the anti-glare
equipment.

Fig. 8-3: Anti-glare equipment, dimensions, R800

Dimensions of anti-glare equipment, R1000

The following figure (>>> Fig. 8-4) shows the dimensions of the anti-glare
equipment.

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Fig. 8-4: Anti-glare equipment, dimensions, R1000

Transportation

The components must be suitably and properly packaged prior to trans-

portation. The components must be protected against damage with shock-
resistant 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 suita-
ble approved padding materials.
Mark transport cases and packing according to the sensitivity of their con-
tents (e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure
correct transportation (e.g. indication of center of gravity). In addition to
these measures, the regulations and conditions of the company entrusted
with the transportation are to be observed.

Start-up and recommissioning

• Reach of R600
(>>> 8.1.1 "Putting the anti-glare equipment R600 into operation"
Page 105)
• Reach of R800
(>>> 8.1.2 "Putting the anti-glare equipment R800 into operation"
Page 112)
• Reach of R1000
(>>> 8.1.3 "Putting the anti-glare equipment R1000 into operation"
Page 120)

Maintenance

The maintenance intervals given in the tables are valid for the operating
conditions specified in the technical data. KUKA Deutschland GmbH must
be consulted in the case of discrepancies!

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Fig. 8-5: Maintenance work (example)

Interval Item Activity

6 months 1 Check all screwed connections (tightening torques).

Decommissioning

(>>> 8.1.4 "Decommissioning" Page 129)

Storage

If components are to be put into long-term storage, the following points

must be observed:
• Clean the components and protect against corrosion.
• The place of storage must be as dry and dust-free as possible.
• Protect mechanical components against damage.
• Avoid temperature fluctuations.
• Avoid wind and drafts.
• Avoid condensation.
• Use appropriate packaging that can withstand the expected environ-
mental conditions.
• Do not leave any loose parts on the product, especially ones that
might knock against other parts.
• Do not expose to direct sunlight.
• Observe and comply with the permissible temperature ranges for stor-
age.
• Select a storage location in which the packaging materials cannot be
damaged.

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Disposal

When the assembly reaches the end of its useful life, it can be removed
and dismantled, and the materials can be disposed of properly by type.
The following table provides an overview of the materials used. All plastic
components are marked with a material designation and must be disposed
of accordingly.
Subassembly, com- Additional informa-
Material
ponent tion
Metals
Steel Screws, washers, sup-
ports, reinforcements,
panels, brackets

8.1.1 Putting the anti-glare equipment R600 into operation

Description

The following instructions describe the installation of the anti-glare equip-

ment.

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. 5 Nm to 50 Nm

Material

The following material is required:

Designation Article number Quantity
Glare shield R600 0000-368-942 1

Tightening torques

The tightening torques can be found under: (>>> 9.1 "Tightening torques"
Page 143)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification 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 is deenergized.
• The positioner must be mechanically secured to prevent unintentional
motions.
• There is no fixture and no tool mounted on the positioner.

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• 2 instructed persons are required for performing this task.

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 opera-
tion.

8.1.1.1 Fastening the anti-glare equipment

Procedure

1. Fasten 2 long brackets to the rotating column with 5 M8x20-8.8 Allen

screws and conical spring washers in each case (>>> Fig. 8-6).
2. Tighten 5 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

Fig. 8-6: Long brackets

1 Long bracket
2 M8x20-8.8 Allen screw (5x)

3. Fasten 1 center upright element to each long bracket with 6

M8x20-8.8 Allen screws and conical spring washers (>>> Fig. 8-7).
4. Tighten 6 M8x20-8.8 Allen screws with conical spring washers on
each upright element with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

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Fig. 8-7: Upright element, center

1 Long bracket
2 M8x20-8.8 Allen screw (6x)

5. Position the center element between the 2 long brackets and fasten
using 6 M8x20-8.8 Allen screws and conical spring washers
(>>> Fig. 8-8).
6. Tighten 6 M8x20-8.8 Allen screws with conical spring washers with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.

Fig. 8-8: Element, center

1 Element, center
2 Upright element, center
3 M8x20-8.8 Allen screw (6x)

7. At the rear of the positioner, fasten each of the 2 short brackets to the
rotating column with 5 M8x20-8.8 Allen screws and conical spring
washers and to the center upright element with 3 M8x20-8.8 Allen
screws and conical spring washers (>>> Fig. 8-9).
8. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

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Fig. 8-9: Short brackets

1 Upright element, center

2 Short bracket
3 Rotating column
4 M8x20-8.8 Allen screws (5x) on rotating column
5 M8x20-8.8 Allen screws (3x) on upright element, center

9. Fasten 1 center upper bracket to the 2 upright elements and to the

center element with 7 M8x20-8.8 Allen screws and conical spring
washers (>>> Fig. 8-10).
10. Tighten 7 M8x20-8.8 Allen screws with conical spring washers with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.

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Fig. 8-10: Upper bracket, center

1 M8x20-8.8 Allen screw (7x)

2 Upper bracket, center
3 Element, center
4 Upright element, center

11. Fasten 1 upright element to each center upright element using 5

M8x20-8.8 Allen screws and conical spring washers (>>> Fig. 8-11).
12. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each upright element with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

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Fig. 8-11: Upright element

1 Upright element
2 Upright element, center
3 M8x20-8.8 Allen screw (5x)

13. Fasten 1 bracket to each upright element using 4 M8x20-8.8 Allen

screws and conical spring washers. (>>> Fig. 8-12)
14. Tighten 4 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

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Fig. 8-12: Bracket, upper

1 Bracket, upper
2 M8x20-8.8 Allen screw (4x)
3 Upright element
4 Upright element, center

15. Fasten 2 reinforcements to the upright elements with 3 M8x20-8.8 Al-

len screws and conical spring washers and to the rotating column with
4 Allen screws and conical spring washers (>>> Fig. 8-13).
16. Tighten 7 M8x20-8.8 Allen screws with conical spring washers on
each reinforcement with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

Fig. 8-13: Reinforcement

1 M8x20-8.8 Allen screws (5x) on upright elements

2 Reinforcement
3 Upright element R1000
4 Upright element
5 M8x20-8.8 Allen screws (4x) on rotating column

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17. Fasten 2 cover plates to the rotating column with 3 M5x10-8.8 round
head screws and to the center element with 3 M8x20-8.8 Allen screws
and conical spring washers (>>> Fig. 8-14).
18. Tighten 6 M5x10-8.8 round head screws on each cover plate with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.
19. Tighten 6 M8x20-8.8 Allen screws on each cover plate with a torque
wrench in diagonally opposite sequence. Increase the tightening tor-
que to the specified value in several stages.

Fig. 8-14: Cover plate

1 Element, center
2 M8x20-8.8 Allen screws (3x each) on element, center
3 Cover plate
4 M5x10-8.8 round head screws (3x each) on rotating column
5 Rotating column

8.1.1.2 Concluding work

The following concluding work must be carried out:

• Carry out a test run in T1 mode and look out for irregularities.

8.1.2 Putting the anti-glare equipment R800 into operation

Description

The following instructions describe the installation of the anti-glare equip-

ment.

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. 5 Nm to 50 Nm

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Material

The following material is required:

Designation Article number Quantity
Glare shield R800 0000-368-943 1

Tightening torques

The tightening torques can be found under: (>>> 9.1 "Tightening torques"
Page 143)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification 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 is deenergized.
• The positioner must be mechanically secured to prevent unintentional
motions.
• There is no fixture and no tool mounted on the positioner.
• 2 instructed persons are required for performing this task.

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 opera-
tion.

8.1.2.1 Fastening the anti-glare equipment

Procedure

1. Fasten 2 long brackets to the rotating column with 5 M8x20-8.8 Allen

screws and conical spring washers in each case (>>> Fig. 8-15).
2. Tighten 5 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

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Fig. 8-15: Long brackets

1 Long bracket
2 M8x20-8.8 Allen screw (5x)

3. Fasten 1 center upright element to each long bracket with 6

M8x20-8.8 Allen screws and conical spring washers (>>> Fig. 8-16).
4. Tighten 6 M8x20-8.8 Allen screws with conical spring washers on
each upright element with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

Fig. 8-16: Upright element, center

1 Long bracket
2 M8x20-8.8 Allen screw (6x)

5. Position the center element between the 2 long brackets and fasten
using 6 M8x20-8.8 Allen screws and conical spring washers
(>>> Fig. 8-17).

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6. Tighten 6 M8x20-8.8 Allen screws with conical spring washers with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.

Fig. 8-17: Element, center

1 Element, center
2 Upright element, center
3 M8x20-8.8 Allen screw (6x)

7. At the rear of the positioner, fasten each of the 2 short brackets to the
rotating column with 5 M8x20-8.8 Allen screws and conical spring
washers and to the center upright element with 3 M8x20-8.8 Allen
screws and conical spring washers (>>> Fig. 8-18).
8. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

Fig. 8-18: Short brackets

1 Upright element, center

2 Short bracket

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3 Rotating column
4 M8x20-8.8 Allen screws (5x) on rotating column
5 M8x20-8.8 Allen screws (3x) on upright element, center

9. Fasten 1 center upper bracket to the 2 upright elements and to the

center element with 7 M8x20-8.8 Allen screws and conical spring
washers (>>> Fig. 8-19).
10. Tighten 7 M8x20-8.8 Allen screws with conical spring washers with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.

Fig. 8-19: Upper bracket, center

1 M8x20-8.8 Allen screw (7x)

2 Upper bracket, center
3 Element, center
4 Upright element, center

11. Fasten 1 upright element to each center upright element using 5

M8x20-8.8 Allen screws and conical spring washers (>>> Fig. 8-20).
12. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each upright element with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

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Fig. 8-20: Upright element

1 Upright element
2 Upright element, center
3 M8x20-8.8 Allen screw (5x)

13. Fasten 1 bracket to each upright element using, initially, 4 M8x20-8.8

Allen screws and conical spring washers (>>> Fig. 8-21).
14. Tighten 4 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

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Fig. 8-21: Bracket, upper

1 Bracket, upper
2 M8x20-8.8 Allen screw (4x)
3 Upright element
4 Upright element, center

15. Fasten 1 upright element R800 to each upright element using 5

M8x20-8.8 Allen screws and conical spring washers and to the upper
bracket using 3 M8x20-8.8 Allen screws and conical spring washers
(>>> Fig. 8-22).
16. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each upright element R800 with a torque wrench in diagonally oppo-
site sequence. Increase the tightening torque to the specified value in
several stages.

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Fig. 8-22: Upright element R800

1 M8x20-8.8 Allen screw (3x)

2 M8x20-8.8 Allen screw (5x)
3 Upright element
Upright element R1000

17. Fasten 2 reinforcements to the upright elements with 5 M8x20-8.8 Al-

len screws and conical spring washers and to the rotating column with
4 Allen screws and conical spring washers (>>> Fig. 8-23).
18. Tighten 9 M8x20-8.8 Allen screws with conical spring washers on
each reinforcement with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

Fig. 8-23: Reinforcement

1 M8x20-8.8 Allen screws (5x) on upright elements

2 Reinforcement

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3 Upright element R800

4 Upright element
5 M8x20-8.8 Allen screws (4x) on rotating column

19. Fasten 2 cover plates to the rotating column with 3 M5x10-8.8 round
head screws and to the center element with 3 M8x20-8.8 Allen screws
and conical spring washers (>>> Fig. 8-24).
20. Tighten 6 M5x10-8.8 round head screws on each cover plate with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.
21. Tighten 6 M8x20-8.8 Allen screws on each cover plate with a torque
wrench in diagonally opposite sequence. Increase the tightening tor-
que to the specified value in several stages.

Fig. 8-24: Cover plate

1 Element, center
2 M8x20-8.8 Allen screws (3x each) on element, center
3 Cover plate
4 M5x10-8.8 round head screws (3x each) on rotating column
5 Rotating column

8.1.2.2 Concluding work

The following concluding work must be carried out:

• Carry out a test run in T1 mode and look out for irregularities.

8.1.3 Putting the anti-glare equipment R1000 into operation

Description

The following instructions describe the installation of the anti-glare equip-

ment.

Equipment

The following equipment is required:

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Designation Article number
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 5 Nm to 50 Nm

Material

The following material is required:

Designation Article number Quantity
Glare shield R1000 0000-368-944 1

Tightening torques

The tightening torques can be found under: (>>> 9.1 "Tightening torques"
Page 143)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification 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 is deenergized.
• The positioner must be mechanically secured to prevent unintentional
motions.
• There is no fixture and no tool mounted on the positioner.
• 2 instructed persons are required for performing this task.

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 opera-
tion.

8.1.3.1 Fastening the anti-glare equipment

Procedure

1. Fasten 2 long brackets to the rotating column with 5 M8x20-8.8 Allen

screws and conical spring washers in each case (>>> Fig. 8-25).
2. Tighten 5 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

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Fig. 8-25: Long brackets

1 Long bracket
2 M8x20-8.8 Allen screw (5x)

3. Fasten 1 center upright element to each long bracket with 6

M8x20-8.8 Allen screws and conical spring washers (>>> Fig. 8-26).
4. Tighten 6 M8x20-8.8 Allen screws with conical spring washers on
each upright element with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

Fig. 8-26: Upright element, center

1 Long bracket
2 M8x20-8.8 Allen screw (6x)

5. Position the center element between the 2 long brackets and fasten
using 6 M8x20-8.8 Allen screws and conical spring washers
(>>> Fig. 8-27).

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6. Tighten 6 M8x20-8.8 Allen screws with conical spring washers with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.

Fig. 8-27: Element, center

1 Element, center
2 Upright element, center
3 M8x20-8.8 Allen screw (6x)

7. At the rear of the positioner, fasten each of the 2 short brackets to the
rotating column with 5 M8x20-8.8 Allen screws and conical spring
washers and to the center upright element with 3 M8x20-8.8 Allen
screws and conical spring washers (>>> Fig. 8-28).
8. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

Fig. 8-28: Short brackets

1 Upright element, center

2 Short bracket

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3 Rotating column
4 M8x20-8.8 Allen screws (5x) on rotating column
5 M8x20-8.8 Allen screws (3x) on upright element, center

9. Fasten 1 center upper bracket to the 2 upright elements and to the

center element with 7 M8x20-8.8 Allen screws and conical spring
washers (>>> Fig. 8-29).
10. Tighten 7 M8x20-8.8 Allen screws with conical spring washers with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.

Fig. 8-29: Upper bracket, center

1 M8x20-8.8 Allen screw (7x)

2 Upper bracket, center
3 Element, center
4 Upright element, center

11. Fasten 1 upright element to each center upright element using 5

M8x20-8.8 Allen screws and conical spring washers (>>> Fig. 8-30).
12. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each upright element with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

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Fig. 8-30: Upright element

1 Upright element
2 Upright element, center
3 M8x20-8.8 Allen screw (5x)

13. Fasten 1 bracket to each upright element using, initially, 4 M8x20-8.8

Allen screws and conical spring washers (>>> Fig. 8-31).
14. Tighten 4 M8x20-8.8 Allen screws with conical spring washers on
each bracket with a torque wrench in diagonally opposite sequence.
Increase the tightening torque to the specified value in several stages.

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Fig. 8-31: Bracket, upper

1 Bracket, upper
2 M8x20-8.8 Allen screw (4x)
3 Upright element
4 Upright element, center

15. Fasten 1 upright element R1000 to each upright element using 5

M8x20-8.8 Allen screws and conical spring washers and to the upper
bracket using 3 M8x20-8.8 Allen screws and conical spring washers
(>>> Fig. 8-32).
16. Tighten 8 M8x20-8.8 Allen screws with conical spring washers on
each upright element R1000 with a torque wrench in diagonally oppo-
site sequence. Increase the tightening torque to the specified value in
several stages.

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Fig. 8-32: Upright element R1000

1 M8x20-8.8 Allen screw (3x)

2 M8x20-8.8 Allen screw (5x)
3 Upright element
4 Upright element R1000

17. Fasten 2 reinforcements to the upright elements with 5 M8x20-8.8 Al-

len screws and conical spring washers and to the rotating column with
4 Allen screws and conical spring washers (>>> Fig. 8-33).
18. Tighten 9 M8x20-8.8 Allen screws with conical spring washers on
each reinforcement with a torque wrench in diagonally opposite se-
quence. Increase the tightening torque to the specified value in
several stages.

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Fig. 8-33: Reinforcement

1 M8x20-8.8 Allen screws (5x) on upright elements

2 Reinforcement
3 Upright element R1000
4 Upright element
5 M8x20-8.8 Allen screws (4x) on rotating column

19. Fasten 2 cover plates to the rotating column with 3 M5x10-8.8 round
head screws and to the center element with 3 M8x20-8.8 Allen screws
and conical spring washers (>>> Fig. 8-34).
20. Tighten 6 M5x10-8.8 round head screws on each cover plate with a
torque wrench in diagonally opposite sequence. Increase the tighten-
ing torque to the specified value in several stages.
21. Tighten 6 M8x20-8.8 Allen screws on each cover plate with a torque
wrench in diagonally opposite sequence. Increase the tightening tor-
que to the specified value in several stages.

Fig. 8-34: Cover plate

1 Element, center
2 M8x20-8.8 Allen screws (3x each) on element, center
3 Cover plate
4 M5x10-8.8 round head screws (3x each) on rotating column

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5 Rotating column

8.1.3.2 Concluding work

The following concluding work must be carried out:

• Carry out a test run in T1 mode and look out for irregularities.

8.1.4 Decommissioning

Description

This section describes all the tasks which are necessary for decommis-
sioning the anti-glare equipment. After decommissioning, it is prepared for
storage or for transportation to a different location.

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

Precondition

• The positioner controller must be switched off and secured to prevent

unauthorized persons from switching it on again.
• The power cable is deenergized.
• The positioner must be mechanically secured to prevent unintentional
motions.
• There is no fixture and no tool mounted on the positioner.
• 2 instructed persons are required for performing this task.

Precondition

• The positioner controller must be switched off and secured to prevent

unauthorized persons from switching it on again.
• The power cable is 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 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 opera-
tion.

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8.1.4.1 Moving the positioner into its transport position

Options

Procedure

1. Secure positioner.
2. Remove tools and equipment.
3. Put the positioner into operation and move it into the transport posi-
tion.

Fig. 8-35: Transport position

4. Secure the positioner by pressing the E-STOP device and then shut
down the positioner.

8.1.4.2 Removing the anti-glare equipment

Procedure

1. Unscrew 3 M8x20-8.8 Allen screws together with conical spring wash-

ers from both cover plates (>>> Fig. 8-36).
2. Unscrew 3 M5x10-8.8 round head screws from both cover plates and
remove the cover plates.
3. Unscrew the following Allen screws with conical spring washers from
the reinforcements and remove the reinforcements:
• Anti-glare equipment R600: 3 M8x20-8.8 Allen screws in each
case
• Anti-glare equipment R800/R1000: 5 M8x20-8.8 Allen screws in
each case
4. On the anti-glare equipment R800 and R1000, unscrew 8 M8x20-8.8
Allen screws with conical spring washers from each upright element
R800/R1000 and remove the upright elements R800/R1000.
5. Unscrew the following Allen screws with conical spring washers from
the upper brackets and remove the upper brackets:
• Anti-glare equipment R600: 4 M8x20-8.8 Allen screws in each
case
• Anti-glare equipment R800/R1000: 6 M8x20-8.8 Allen screws in
each case
6. Unscrew 5 M8x20-8.8 Allen screws with conical spring washers from
each upright element and remove the upright elements.

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7. Unscrew 7 M8x20-8.8 Allen screws with conical spring washers from
the center upper bracket and remove the center upper bracket.
8. From each short bracket, unscrew 5 M8x20-8.8 Allen screws and con-
ical spring washers on the rotating column and 3 M8x20-8.8 Allen
screws and conical spring washers on the center upright element and
remove the center upright element.
9. From each upright element, unscrew 5 M8x20-8.8 Allen screws and
conical spring washers on the rotating column and 3 M8x20-8.8 Allen
screws and conical spring washers on the center upright element and
remove the center upright element.
10. Unscrew 6 M8x20-8.8 Allen screws with conical spring washers from
the center element and remove the center element.
11. Unscrew 6 M8x20-8.8 Allen screws with conical spring washers from
each center upright element and remove the center upright elements.
12. Unscrew 5 M8x20-8.8 Allen screws with conical spring washers from
each long bracket and remove the long brackets.

Fig. 8-36: Removing the anti-glare equipment (example)

1 Screw connection of upright element R800/R1000 to upright ele-

ment
2 Screw connection of upright element to upright element, center
3 Screw connection of upright element, center to elements, center
4 Screw connection of cover plate
5 Screw connection of upper bracket and upper bracket, center

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6 Screw connection of long bracket

7 Screw connection of reinforcement

8.1.4.3 Concluding work

The following concluding work must be carried out:

• Prepare the positioner for storage if it is not to be reinstalled.

8.2 Weld current return, infinitely rotating (optional)

Description

The infinitely rotating weld current return 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 dis-
charged via the weld current return.
Using this weld current return allows the respective rotational axis to be
designed as an infinitely rotating axis.
This weld current return consists of the following components:
• Current collector:
‒ Contact surface of plunger holder
‒ Plunger holder with integrated compression spring
‒ Connection plate
‒ Holder
‒ Insulating plate
• Fastening materials
• Grounding cables

Fig. 8-37: Components, infinitely rotating weld current return, exam-

ple

1 Plunger holder 4 Insulating plate

2 Copper bar 5 Grounding cables
3 Holder 6 Current collector

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Basic data

Weight, current collector approx. 3.3 kg

Article number 0000-363-444
Current rating under continuous max. 500 A
load

Further information about the ambient conditions is contained in the as-

sembly instructions for the robot and robot controller.

Dimensions

The following diagram shows the dimensions of the current collector for:

Fig. 8-38: Dimensions, current collector

Planning

A welding robot can be connected to interface A1.

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Fig. 8-39: Interface A1

1 Connection, weld current return, 1st robot, Dinse DIX BE 70/95

2 Motor cable XM11
3 Motor cable XM9
4 Data cable to RDC X31.1
5 Data cable from RDC X21.1 to cascadable RDC
6 Motor cable XM7
7 Motor cable XM10
8 Motor cable XM8

Transportation

The components must be suitably and properly packaged prior to trans-

portation. The components must be protected against damage with shock-
resistant 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 suita-
ble approved padding materials.
Mark transport cases and packing according to the sensitivity of their con-
tents (e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure
correct transportation (e.g. indication of center of gravity). In addition to
these measures, the regulations and conditions of the company entrusted
with the transportation are to be observed.

Start-up and recommissioning

Start-up and recommissioning may only be carried out by KUKA Deutsch-

land GmbH or trained specialist personnel.

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Maintenance

Fig. 8-40: Maintenance chart, current collector, example

Interval Item Activity

6 months 1 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 ex-
changed.
(>>> 8.2.1 "Exchanging the current collector" Page 136)
6 months 2 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 ex-
changed.
(>>> 8.2.1 "Exchanging the current collector" Page 136)
6 months 3 Check tightening torques for screws.

Repair

(>>> 8.2.1 "Exchanging the current collector" Page 136)

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.
Subassembly, com- Additional informa-
Material
ponent tion
Metals
Copper Cables, wires -

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Subassembly, com- Additional informa-

Material
ponent tion
Steel Connection plate, -
screws, washers, hold-
ers
Plunger holder Dispose of plunger
holder without disman-
tling.
Plastics
HGW2082 Insulating plate -
PUR Cable sheaths -

8.2.1 Exchanging the current collector

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
AG current collector 500A 0000-363-444 1

Procurement of spare parts

Defective components must only be replaced with original spare parts

from KUKA Deutschland GmbH. Non-compliance nullifies warranty and lia-
bility claims.
A “Repair Card” is supplied with the exchange parts. This must be com-
pleted and returned to KUKA Deutschland GmbH together with the defec-
tive 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: (>>> 9.1 "Tightening torques"
Page 143)
These are valid for screws and nuts where no other specifications are giv-
en.

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Screws of strength class 10.9 and higher as well as screws with test cer-

Options
tification 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.

8.2.1.1 Removing the current collector on the drive side

Procedure

1. Unscrew the cable gland from the copper bar (>>> Fig. 8-41).
2. Take the cable gland and cable off the copper bar.
3. Unscrew 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 in-
sulating bushings from the current collector.
4. Remove the current collector carefully from the drive unit.

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Fig. 8-41: Current collector

1 Copper bar
2 M8x25-8.8-A2K Allen screw with washer and insulating bushing

8.2.1.2 Installing the current collector on the drive side

Procedure

1. Position the current collector in the drive unit 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. 8-42).
2. Place the cable on the copper bar and fasten it with the cable gland.

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Fig. 8-42: Current collector

1 Copper bar
2 M8x25-8.8-A2K Allen screw with washer and insulating bushing

8.2.1.3 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.

8.3 Position monitoring

The positioner can be equipped with safe position monitoring on the main
axis in order to detect the working position of the main axis. The signal
can be sent to a controller or PLC.
The position monitoring consists of the following components:
• Safety switch
• Actuator for safety switch
• Bus module (PROFINET)
• Cables and hoses M12
• Plates
• Fastening materials

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Fig. 8-43: Position monitoring

1 Guard plate
2 Mounting plate
3 Safety switch
4 Cable M12
5 Actuator for safety switch
6 Bus module (PROFINET)

Basic data

Designation Article number Weight

Position sensing 0000-354-776 approx.
3.5 kg

Further information about the ambient conditions is contained in the as-

sembly instructions for the robot and robot controller.

Transportation

The components must be suitably and properly packaged prior to trans-

portation. The components must be protected against damage with shock-
resistant 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 suita-
ble approved padding materials.
Mark transport cases and packing according to the sensitivity of their con-
tents (e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure
correct transportation (e.g. indication of center of gravity). In addition to
these measures, the regulations and conditions of the company entrusted
with the transportation are to be observed.

Start-up and recommissioning

Start-up and recommissioning may only be carried out by KUKA Deutsch-

land GmbH or trained specialist personnel.

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Maintenance

The maintenance intervals given in the tables are valid for the operating
conditions specified in the technical data. KUKA Deutschland GmbH must
be consulted in the case of discrepancies!

Fig. 8-44: Maintenance work

Interval Item Activity

6 months 1 Check all screwed connections (tightening torques).

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.
Subassembly, com- Additional informa-
Material
ponent tion
Metals
Copper Cables, wires -
Steel Plates, screws, wash- -
ers
Electrical parts
Safety switch, actuator Dispose of as electri-
for safety switch cal scrap without dis-
assembling
Plastics
PUR Cable sheaths -

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Appendix
9 Appendix

9.1 Tightening torques

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 10.9
ISO7991 ISO7380, ISO07381
Allen screw 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.

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9.2 Auxiliary and operating materials used

Product designation / Use Manufacturer designation /

Article number Address

Optigear Synt. Gear oil Castrol Industries - divisie BP Euro-

ALR 150_EEA pa SE - BP Belgium
Amocolaan 2
0000-362-835 for Europe-
2440 Geel
an Economic Area
Belgium
Optigear Synt.
ALR 150_USA
0000-361-461 for USA,
Canada, Mexico
Optigear Synt.
ALR 150_CHN
0000-361-473 for China
Optigear Synt.
ALR 150_APA
0000-361-476 for Asia/
Pacific Area
Article numbers for further
regions can be found in
KUKA Xpert.

Optitemp RB 2 Lubricating grease Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
0000-101-456
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany

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.

9.3 Applied standards and regulations

Name/Edition Definition

2006/42/EC:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)

2014/68/EU:2014 Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)

EN 60204-1:2006/ Safety of machinery:

A1:2009
Electrical equipment of machines - Part 1: General requirements

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Appendix
EN 61000-6-2:2005 Electromagnetic compatibility (EMC):
Part 6-2: Generic standards; Immunity for industrial environments

EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments

EN 614-1:2006+A1:2009 Safety of machinery:

Ergonomic design principles - Part 1: Terms and general principles

EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, 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

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

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KUKA Service
10 KUKA Service

10.1 Requesting support

Introduction

This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.

Information

The following information is required for processing a support re-

quest:
• 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 rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ 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 modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used

10.2 KUKA Customer Support

The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

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Index Declaration of conformity............................... 18

Declaration of incorporation.....................17, 18
2006/42/EC:2006.......................................... 144
Decommissioning................................... 30, 129
2014/68/EU:2014.......................................... 144
Description, positioner.................................... 11
95/16/EC....................................................... 144
Dimensions, transport.....................................81
Directives...................................................... 144
Disclaimer....................................................... 17
A Disposal.......................................................... 30
Accessories.............................................. 13, 17 Documentation, positioning system................. 7
ANSI/RIA R.15.06-2012............................... 145 Drive unit.......................................................... 8
Anti-glare equipment (optional).................... 101
Anti-glare equipment R1000, putting into
operation.......................................................120
Anti-glare equipment R600, putting into
E
EC declaration of conformity......................... 18
operation.......................................................105
Electrical installations..................................... 13
Anti-glare equipment R800, putting into
Electromagnetic compatibility (EMC)........... 145
operation....................................................... 112
Electromagnetic compatibility (EMC):.......... 145
Appendix....................................................... 143
EMC Directive.................................................18
Automatic mode..............................................28
EMD.................................................................. 8
Auxiliary materials used............................... 144
EN 60204-1:2006/A1:2009........................... 144
Axis data........................ 33, 39, 45, 51, 57, 63
EN 61000-6-2:2005...................................... 145
Axis data, KP5-V2S2V1000 R1000............... 63
EN 61000-6-4:2007 + A1:2011.................... 145
Axis data, KP5-V2S2V1000 R600................. 51
EN 614-1:2006+A1:2009..............................145
Axis data, KP5-V2S2V1000 R800................. 57
EN ISO 10218-1:2011.................................. 145
Axis data, KP5-V2S2V500 R1000................. 45
EN ISO 12100:2010..................................... 145
Axis data, KP5-V2S2V500 R600................... 33
EN ISO 13849-1:2015..................................145
Axis data, KP5-V2S2V500 R800................... 39
EN ISO 13849-2:2012..................................145
Axis limitation, mechanical............................. 22
EN ISO 13850:2015..................................... 145
Axis range.................................................. 8, 18
Energy supply system.................................... 11
External axes..................................................17
External axis...............................................9, 20
B
Base frame..................................................... 12
Basic data, KP5-V2S2V1000 R1000............. 61
Basic data, KP5-V2S2V1000 R600............... 49
F
Face plates, dimensions................................ 78
Basic data, KP5-V2S2V1000 R800............... 55
Faults.............................................................. 25
Basic data, KP5-V2S2V500 R1000............... 43
Foundation loads, KP5-V2S2V1000 R1000.. 66
Basic data, KP5-V2S2V500 R600................. 32
Foundation loads, KP5-V2S2V1000 R600.... 54
Basic data, KP5-V2S2V500 R800................. 37
Foundation loads, KP5-V2S2V1000 R800.... 60
Brake defect................................................... 24
Foundation loads, KP5-V2S2V500 R1000.... 48
Brake release device......................................23
Foundation loads, KP5-V2S2V500 R600...... 36
Braking distance.........................................8, 18
Foundation loads, KP5-V2S2V500 R800...... 42
Function test................................................... 26
C
CE mark..........................................................18
Center of gravity.............................................81
G
Cleaning work.................................................29 General safety measures............................... 23
Connecting cable, standard........................... 99
Connecting cables.. 17, 33, 38, 44, 50, 56, 62,
79, 98 H
Connecting cables interface...........................99 Handling equipment...........................82, 86, 94
Connecting cables, connecting................88, 95 Hazardous substances................................... 29
Counterbalancing system............................... 29
Current collector on drive side, removing... 137
Current collector, exchanging...................... 136 I
Industrial robot................................................17
Installation with mounting base..................... 87
D Interface A1.................................................... 79
Danger zone...............................................8, 19 Interface, energy supply system....................80

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Interfaces........................................................ 79 PLC................................................................... 9
Introduction....................................................... 7 Position monitoring....................................... 139
Positioner........................................................ 17
Positioner, mastering................................89, 96
K Pressure Equipment Directive............... 29, 144
KCP......................................................8, 19, 24 Preventive maintenance work........................ 29
Keyboard, external......................................... 24 Product description......................................... 11
KP..................................................................... 8 Protective equipment, overview..................... 21
KR C................................................................. 8 PSA.................................................................20
KUKA Customer Support............................. 147
KUKA Service...............................................147
KUKA smartPAD........................................ 8, 19 R
KUKA smartPAD-2..................................... 8, 19 RDC.................................................................. 9
Reaction distance.......................................8, 18
Recommissioning..................................... 25, 85
L Regulations................................................... 144
Labeling.......................................................... 23 Release device............................................... 23
Lifting tackle....................................................83 Repair............................................................. 28
Linear unit.......................................................17 Robot controller.............................................. 17
Low Voltage Directive.....................................18

S
M Safety..............................................................17
Machine data............................................89, 95 Safety instructions............................................ 7
Machine frame mounting................................76 Safety of machinery.............................144, 145
Machine frame mounting, installing............... 94 Safety options.................................................19
Machinery Directive................................18, 144 Safety zone..........................................9, 19, 21
Maintenance................................................... 28 Safety, general................................................17
Manipulator.......................................... 9, 17, 19 Service life...................................................... 19
Manual mode..................................................27 smartPAD............................................. 9, 19, 24
Mechanical end stops.................................... 22 Software..........................................................17
Misuse.............................................................14 Spare parts................................................... 136
Mounting base................................................ 87 Standards......................................................144
Mounting base with centering........................73 Start-up.....................................................25, 85
Mouse, external.............................................. 24 Start-up, positioner (machine frame
mounting)........................................................ 92
Start-up, positioner (mounting base)............. 85
STOP 0................................................ 9, 19, 72
O STOP 1...................................................... 9, 19
Operating materials used............................. 144
STOP 2...................................................... 9, 20
Operators........................................................ 21
Stop category 0......................................... 9, 19
Optigear Synt. ALR 150...............................144
Stop category 1......................................... 9, 19
Options.............................................13, 17, 101
Stop category 2......................................... 9, 20
Optitemp RB 2..............................................144
Stop category 1, Drive Ramp Stop............... 20
Overload......................................................... 24
STOP 1 - DRS............................................... 20
Overview, positioner....................................... 11
Stopping distance.......................................8, 18
Stopping distances......................................... 72
Storage........................................................... 30
P Support request............................................ 147
Payloads, KP5-V2S2V1000 R1000............... 66 System integrator.............................. 18, 20, 21
Payloads, KP5-V2S2V1000 R600................. 53
Payloads, KP5-V2S2V1000 R800................. 60
Payloads, KP5-V2S2V500 R1000................. 48 T
Payloads, KP5-V2S2V500 R600................... 36
T1 (operating mode).................................. 9, 20
Payloads, KP5-V2S2V500 R800................... 42
T2 (operating mode).................................. 9, 20
Personal protective equipment...................... 20
Teach pendant................................................ 17
Personnel........................................................20
Technical data.................................................31
Planning.......................................................... 73
Technical data, KP5-V2S2V1000 R1000.......61
Plant integrator............................................... 20
Technical data, KP5-V2S2V1000 R600.........49
Plates and labels............................................67
Technical data, KP5-V2S2V1000 R800.........55

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Technical data, KP5-V2S2V500 R1000.........43

Technical data, KP5-V2S2V500 R600...........32
Technical data, KP5-V2S2V500 R800...........37
Technical data, overview................................ 31
Terms used....................................................... 8
Terms, safety.................................................. 18
Tightening torques........................................143
Training............................................................. 7
Transport position.................................... 81, 92
Transportation.......................................... 25, 81
Turn-tilt table...................................................17

U
Use
Intended..................................................... 14
User.......................................................... 18, 20

W
Warnings........................................................... 7
Weld current return, infinitely rotating
(optional).......................................................132
Workspace........................................... 8, 18, 21

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