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Robot Option KUKA Roboter GmbH

Energy Supply Systems A3 - A6

Project: Renault X82


For Product Family KR QUANTEC
Assembly and Operating Instructions

Issued: 14.06.2013

Version: MA ES KR QUANTEC A3-A6 Renault X82 V1 en (PDF)


Specific customer version
Energy Supply Systems A3 - A6 Specific customer version

© Copyright 2013
KUKA Roboter 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 Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

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Book structure: MA ES KR QUANTEC A3-A6 Renault X82 V1.1
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Specific customer version Contents

Contents
1 Introduction .................................................................................................. 5
1.1 Documentation for the options ................................................................................... 5
1.2 Representation of warnings and notes ...................................................................... 5

2 Purpose ........................................................................................................ 7
2.1 Target group .............................................................................................................. 7
2.2 Intended use .............................................................................................................. 7

3 Product description ..................................................................................... 9


3.1 Description of energy supply system A3 - A6 ............................................................ 9
3.1.1 Description of dress package A3 - A6 .................................................................. 10
3.1.2 Description of the fastening materials, A3 - A6 ..................................................... 11

4 Technical data .............................................................................................. 13


4.1 Basic data .................................................................................................................. 13
4.2 Technical data for welding cables .............................................................................. 13
4.2.1 Welding cable ....................................................................................................... 13
4.3 Technical data for bus cables .................................................................................... 14
4.3.1 Interbus cable ....................................................................................................... 14
4.3.2 Interbus cable ....................................................................................................... 15
4.3.3 Profinet cable ........................................................................................................ 16
4.4 Technical data for motor cables ................................................................................. 17
4.4.1 Motor cable ........................................................................................................... 17
4.5 Technical data for control cables ............................................................................... 18
4.5.1 Control cable ......................................................................................................... 18
4.5.2 Control cable ......................................................................................................... 19
4.6 Technical data for hoses ............................................................................................ 20
4.6.1 Water line, green .................................................................................................. 20
4.6.2 Water line, black ................................................................................................... 21
4.6.3 Air line, red ............................................................................................................ 21

5 Safety ............................................................................................................ 23
5.1 Applied norms and regulations .................................................................................. 23

6 Transportation ............................................................................................. 25
6.1 Transportation of assemblies and components ......................................................... 25

7 Start-up and recommissioning ................................................................... 27


7.1 Starting up energy supply system A3 - A6 ................................................................. 27

8 Maintenance ................................................................................................. 31
8.1 Maintaining the energy supply system ....................................................................... 31
8.2 Cleaning the energy supply system ........................................................................... 31

9 Repair ........................................................................................................... 33
9.1 Exchanging the energy supply system dress package .............................................. 33
9.1.1 Removing dress package A3 - A6 ........................................................................ 33
9.1.2 Installing the dress package ................................................................................. 34
9.2 Exchanging the energy supply system holders .......................................................... 37

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9.2.1 Removing the clamp ............................................................................................. 37


9.2.2 Installing the clamp ............................................................................................... 38

10 Decommissioning, storage and disposal .................................................. 41


10.1 Removing energy supply system A3 - A6 .................................................................. 41
10.2 Storage ...................................................................................................................... 43
10.3 Disposal ..................................................................................................................... 43

11 Appendix ...................................................................................................... 45
11.1 Safety data sheets ..................................................................................................... 45
11.1.1 Safety data sheet for Optitemp RB1 cable grease ............................................... 45
11.1.1.1 Designation of substance/formulation and manufacturer ................................ 45
11.1.1.2 Composition / Information about the components ........................................... 45
11.1.1.3 Possible hazards ............................................................................................. 45
11.1.1.4 First aid measures ........................................................................................... 46
11.1.1.5 Fire-fighting measures ..................................................................................... 46
11.1.1.6 Measures after unintended release ................................................................. 46
11.1.1.7 Handling and storage ...................................................................................... 47
11.1.1.8 Exposure limits and personal protective equipment ........................................ 47
11.1.1.9 Physical and chemical properties .................................................................... 47
11.1.1.10 Stability and reactivity ...................................................................................... 48
11.1.1.11 Toxicological information ................................................................................. 48
11.1.1.12 Ecological information ..................................................................................... 48
11.1.1.13 Disposal information ........................................................................................ 48
11.1.1.14 Transport information ...................................................................................... 49
11.1.1.15 Regulations ..................................................................................................... 49
11.1.1.16 Other information ............................................................................................. 50
11.1.2 Safety data sheet for universal adhesive and sealant type 1342 ......................... 50
11.1.2.1 Designation of substance and manufacturer ................................................... 50
11.1.2.2 Possible hazards ............................................................................................. 50
11.1.2.3 Composition / Information about the components ........................................... 50
11.1.2.4 First aid measures ........................................................................................... 51
11.1.2.5 Fire-fighting measures ..................................................................................... 51
11.1.2.6 Measures after unintended release ................................................................. 51
11.1.2.7 Handling and storage ...................................................................................... 51
11.1.2.8 Exposure limits and personal protective equipment ........................................ 51
11.1.2.9 Physical and chemical data ............................................................................. 51
11.1.2.10 Storage stability and reactivity ......................................................................... 52
11.1.2.11 Toxicological information ................................................................................. 52
11.1.2.12 Ecological information ..................................................................................... 52
11.1.2.13 Transport information ...................................................................................... 52
11.1.2.14 Labeling ........................................................................................................... 53
11.1.2.15 Other information ............................................................................................. 53

12 KUKA Service ............................................................................................... 55


12.1 Requesting support ................................................................................................... 55
12.2 KUKA Customer Support ........................................................................................... 55

Index ............................................................................................................. 63

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Specific customer version 1 Introduction

1 Introduction

1.1 Documentation for the options

The documentation for this option consists of the following parts:


 Assembly and operating instructions for this option
 Parts catalog for this option on storage medium
 Assembly and operating instructions for the higher-level system
Each of these sets of instructions is a separate document.

1.2 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable


that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may


occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if


no precautions are taken.

These warnings mean that damage to property may oc-


cur, if no precautions are taken.

These warnings contain references to safety-relevant information or


general safety measures. These warnings do not refer to individual
hazards or individual precautionary measures.

Notes These hints serve to make your work easier or contain references to further
information.

Tip to make your work easier or reference to further information.

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Specific customer version 2 Purpose

2 Purpose

2.1 Target group

This documentation is aimed at users with the following knowledge and skills:
 Advanced knowledge of mechanical engineering
 Advanced knowledge of electrical and electronic systems
 Knowledge of the robot controller system

For optimal use of our products, we recommend that our customers


take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.

2.2 Intended use

Use The intended use of the energy supply system is the supply of energy to tools
and fixtures on the robot. This includes the transmission of control and mea-
suring signals for activating and monitoring tools and fixtures and the supply
of air and water.
Operating the system within the limits of its intended use also involves contin-
uous observance of the operating and assembly instructions of the robot sys-
tem and its options, with particular reference to the maintenance
specifications.

Misuse Any use or application deviating from the intended use is deemed to be imper-
missible misuse; examples of such misuse include:
 Operation with non-specified fluids
 Operation outside the permissible operating parameters
 Use in potentially explosive environments

This assembly is an integral part of an overall system and may only


be operated in a CE-compliant system.

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Specific customer version 3 Product description

3 Product description

3.1 Description of energy supply system A3 - A6

Overview This description applies to all standard robots of the QUANTEC product se-
ries. Different reaches have no effect on the structure and function of the en-
ergy supply system. The installation situation varies, however, according to
the arm length.
The energy supply system consists of the following principal components:
 Dress package
 Fastening materials
 In-line wrist cover
For use in certain production technologies, the robot can be equipped with an
energy supply system (>>> Fig. 3-1 ) between the arm and the in-line wrist.
An energy supply system consists of a dress package for transmitting the en-
ergy, fluids and signals typical of the technological process concerned, and the
holder assembly required for attaching it to the robot.
The energy supply system A3 - A6 (Fig. 1) is fastened to the arm and in-line
wrist in such a way that it does not impair the robot motion and is protected
against damage. The dress package is secured inside a K box that is installed
on the arm of the robot. It is secured in holder A6 in a ball joint and at its start
on interface A3 in the box clamp. The mounting on axis 6 is designed to permit
the flexible tube to rotate but to prevent it from moving in an axial direction. The
multiple-piece spring stubs pull the dress package back into its starting posi-
tion in the K box after every motion and keep it lightly tensioned. Using a pro-
tector, the compression springs must be adjusted for each application in order
to ensure optimized spring travel. It must be ensured, however, that the com-
pression springs are not completely compressed as this could cause damage
to the system. The extent to which the dress package can be pulled out has
an effect on the range of motion of the in-line wrist.
Fastening to the robot is carried out using the “fastening materials” assembly.
This contains all parts required for fastening the energy supply system to the
robot in accordance with the arm length. The K box is also part of this assem-
bly and is available in several variants.
The energy supply system also includes the in-line wrist cover. Its function is
to enable the flexible tube of the energy supply system to slide over the con-
tours of the arm with as little stress as possible during operation of the robot.
The compact unit can be quickly exchanged without great effort.

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Energy Supply Systems A3 - A6 Specific customer version

Fig. 3-1: Principal components

1 Energy supply system, dress 3 In-line wrist cover


package
2 Fastening materials

3.1.1 Description of dress package A3 - A6

The energy supply system A3 - A6 is centered on the dress package


(>>> Fig. 3-2 ). It bundles all the hoses and electric cables in the energy sup-
ply system for compact routing from interface A3 on the arm to interface A6 on
the tool.
The contents of the dress package depend on the specific application and may
therefore vary greatly. At the two extremes, the dress package can either be
empty, or filled to a maximum of 70% of the cross-section. The following figure
shows an example of one possible configuration.
Interface A3 is located on the arm. From this interface, the cables and hoses
are routed to the box clamp of the K box. The flexible tube of the dress pack-
age is routed through the K box in a loop to the outlet and from here to clamp
A6 on the holder of the mounting flange.

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Specific customer version 3 Product description

Fig. 3-2: Dress package A3 - A6

1 Welding cable 6 Spring holder


2 Multibus cable 7 Ball holder
3 Clamping piece A3 8 Clamping piece A6
4 Corrugated tube 9 Control cable
5 Spring stub 10 Hose lines

The flexible tube is fixed to the spring holder in the box clamp by means of the
support shell. The support shell constitutes the fixed point of the flexible tube,
while the flexible tube is able to slide through the spring holder. The spring
stubs are compressed during motions of the in-line wrist and thus tensioned
so that the flexible tube is pulled back into the K box in the case of motions in
the opposite direction. The pre-tension of the dress package can be modified
by adjusting the protector; this changes the extent to which the dress package
can be pulled out.
The two clamping pieces serve to adjust and locate the cables and hoses in
the dress package and at the transitional points. The number and size of the
holes in the clamping pieces are determined by the composition of the dress
package. Holes that are present but not used must be sealed.

3.1.2 Description of the fastening materials, A3 - A6

The “fastening materials” assembly contains all parts required for fastening
the dress package to the arm. This assembly also contains the fastening ma-
terials for connecting the cables and hoses (>>> Fig. 3-3 ). The scope of the
assembly varies according to the arm length. The figure shows the assembly
for an arm length of 1000 mm (AL1000).
The clip for fastening clamp A6 to the in-line wrist is not part of the “fastening
materials” assembly.

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Fig. 3-3: Fastening materials

1 Clamp, A6 4 Cover, interface A3


2 Clip 5 K box
3 In-line wrist cover 6 Match plate

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Specific customer version 4 Technical data

4 Technical data

4.1 Basic data

Thermal and electrical overloading of multi-strand cables


can damage the energy supply system. Observe and
comply with EN 60204-1.

Ambient temper- Operation 283 K to 328 K (+10 °C to +55 °C)


ature Storage and transpor- 233 K to 333 K (-40 °C to +60 °C)
tation
Humidity rating Humidity class
EN 60204/4.4.4 F

4.2 Technical data for welding cables

4.2.1 Welding cable

Configuration 1x 35 mm2, GNYE


2x 35 mm2, BK
Rated voltage 600 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A3 Pin housing RobiFix S 35 MTB
Connection A6 RobiFix-B35-FZEE, female
Minimum bending 10x outer diameter
radius
Protection class IP 65
when connected

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Fig. 4-1: Welding cable

4.3 Technical data for bus cables

4.3.1 Interbus cable

Configuration 5x (2x 0.25 mm2 shielded)


2x (2x 1.00 mm2 shielded)
1x 1 mm2 GN/YE
Rated voltage 300 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A3 Bus connector, 19-pole, male
Connection A6 Bus connector, 19-pole, female
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected

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Specific customer version 4 Technical data

Fig. 4-2: Interbus cable

4.3.2 Interbus cable

Configuration 5x (2x 0.25 mm2), shielded

2x (2x 1 mm2), shielded

1x 1 mm2 GN/YE
Rated voltage 30 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A3 Bus coupling, 9-pole, male
Connection A6 Bus coupling, 9-pole, female
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected

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Fig. 4-3: Interbus cable

4.3.3 Profinet cable

Configuration 2x (2x AWG22), shielded


Rated voltage 30 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A3 M12
Connection A6 M12
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected

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Specific customer version 4 Technical data

Fig. 4-4: Profinet cable

4.4 Technical data for motor cables

Thermal and electrical overloading of multi-strand cables


can damage the energy supply system. Observe and
comply with EN 60204-1.

4.4.1 Motor cable

Configuration 4x 2.5 mm2 + 2x 1 mm2, overall shield


Rated voltage 450/750 V
Current EN 60204-1 (derating factors must be taken into
account)
Connection A3 Power coupling, 6-pole, size 1
Connection A6 Circular power connector, 6-pole, size 1
Minimum bending 10x outer diameter
radius
Protection class IP 65
when connected

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Fig. 4-5: Motor cable

4.5 Technical data for control cables

Thermal and electrical overloading of multi-strand cables


can damage the energy supply system. Observe and
comply with EN 60204-1.

4.5.1 Control cable

Configuration 13x 0.5 mm2


1x (2x 0.5 mm2), shielded
3x 1 mm2
Rated voltage 63 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A3 Signal coupling, 19-pole, E-part
Connection A6 Signal coupling, 19-pole, P-part
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected

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Fig. 4-6: Control cable

4.5.2 Control cable

Configuration 4x (2x 0.25 mm2),


shielded in pairs
Rated voltage 160 V AC/DC
Current EN 60204-1 (derating factor must be taken into
account)
Connection A3 Signal connector, 12-pole, P part
Connection A6 Connector, 12-pole, E part
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected

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Fig. 4-7: Control cable

4.6 Technical data for hoses

4.6.1 Water line, green

Hose line Hose 1/2", green


Connection A3 Sealing head, straight, M22x1.5 union nut
Connection A6 Sealing head, straight, M20x1.5
Rated pressure max. 2.0 MPa (20 bar)
Hose length See parts catalog
Minimum bending 10x outer diameter
radius
Permissible thermal 243 K to 353 K (-30 °C to +80 °C)
loading

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Specific customer version 4 Technical data

Fig. 4-8: Water line, green

4.6.2 Water line, black

Hose line Hose 1/2", black


Connection A3 Sealing head, straight, M22x1.5 union nut
Connection A6 Sealing head, straight, M20x1.5
Rated pressure max. 2.0 MPa (20 bar)
Hose length See parts catalog
Minimum bending 10x outer diameter
radius
Permissible thermal 243 K to 353 K (-30 °C to +80 °C)
loading

Fig. 4-9: Water line, black

4.6.3 Air line, red

Hose line Hose 1/2", red


Connection A3 Sealing head, straight, union nut, M22x1.5
Connection A6 Sealing head, straight, M20x1.5
Rated pressure max. 2.0 MPa (20 bar)
Hose length See parts catalog
Minimum bending 10x outer diameter
radius
Permissible thermal 243 K to 353 K (-30 °C to +80 °C)
loading

Fig. 4-10: Air line, red

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Specific customer version 5 Safety

5 Safety
For this assembly or option, the safety instructions of the higher-level system
with which it is operated apply. The general safety instructions also apply. All
applicable safety measures required by national law, as well as all regulations
and ordinances for the avoidance of personal injury and material damage,
must likewise be observed at all times.
The relevant personal protective equipment must be worn during performance
of all work on the system, system components or equipment.

5.1 Applied norms and regulations

Name Definition Edition


2004/108/EC EMC Directive: 2004
Directive of the European Parliament and of the
Council of 15 December 2004 on the approximation
of the laws of the Member States relating to electro-
magnetic compatibility and repealing Directive 89/
336/EEC
DIN EN 61000-6-2 Electromagnetic compatibility (EMC): 2005
Part 6-2: Generic standards; Immunity for industrial
environments
DIN EN 61000-6-4 Electromagnetic compatibility (EMC): 2007
Part 6-4: Generic standards; Emission standard for
industrial environments
2006/95/EC Low Voltage Directive: 2006
Directive of the European Parliament and the Council
of 12 December 2006 on the harmonization of the
laws of Member States relating to electrical equip-
ment designed for use within certain voltage limits.
DIN EN 60204-1 Safety of machinery: 2006
Electrical equipment of machines - Part 1: General
requirements

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Specific customer version 6 Transportation

6 Transportation

6.1 Transportation of assemblies and components

The following measures are to be taken before assemblies and individual com-
ponents are transported:
 Clean components.
 Pack the energy supply system in wooden cases with protection against
moisture and transport damage.
For preference, a Euro pallet with raised sides should be used for trans-
porting the energy supply system assembly.
 Wrap interfaces in PVC foil or waxed paper, with desiccant if necessary.
 Assign small parts to their respective components in plastic bags to pre-
vent them from getting lost.
 Provide electrical and optical components with shock-resistant and break-
proof packing.
 Close Harting connectors with metal covers.
 Close circular connectors with universal protectors.
 Close hoses with universal protectors.
 Protect components against impacts and slipping; fill gaps with suitable
approved padding materials.
 Do not pinch or kink the flexible tube.
 Observe the minimum bending radii of all cables and hoses.
 Cover the energy supply system to protect it against dirt and water during
transportation.
The covering must be able to withstand wind and moderate mechanical
strain.
Mark transport cases and packing according to the sensitivity of their contents
(e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure correct
transportation (e.g. indication of center of gravity). In addition to these mea-
sures, the regulations and conditions of the company entrusted with the trans-
portation are to be observed.

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Specific customer version 7 Start-up and recommissioning

7 Start-up and recommissioning

7.1 Starting up energy supply system A3 - A6

Description This description applies to the installation and start-up of all energy supply sys-
tems for A3 - A6 on this robot model. In the following description, work on a
standard version is described. In the case of a different configuration, proceed
accordingly.
The robot can be equipped with different K boxes, but the installation proce-
dure is the same in all cases.
Adjusting the dress package has a major influence on its service life. Great
care and intensive adjustment are rewarded by a longer service life. It may be
useful to modify or add to the programming to reduce the strain on the energy
supply system.

Preconditions  Interface A3 is fully installed.


 The complete energy supply system is present.
 Axes 4, 5 and 6 are as close as possible to the zero position.
 Clamp on A6 is installed and facing upwards.
 The arm is positioned horizontally.
 The robot system is operational, but secured by means of the EMERGEN-
CY STOP button or switched off.

Procedure
Unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

When removing or installing the dress package, there is


a risk of crushing from pre-tensioned springs and hinged
clamps. Wearing protective gloves, carefully remove the dress package with
its pre-tensioned springs from the holders.

1. Place clamp A6 on clip and lightly tighten fastening screws.


2. Mount the match plate and fasten it with 4 M12x25-8.8 flat head screws;
lightly tighten the flat head screws. Observe orientation of the match plate.
In the case of arm length 1200 mm, the match plate and the cover of inter-
face A3 are dispensed with; in the case of arm length 1400 mm, the cover
of interface A3 is dispensed with.
3. Push interface A3 under the match plate and align it; only applicable to
arm length 1000 mm.
4. Tighten the 4 M12x25-8.8 flat head screws with a torque wrench; MA =
78 Nm.
5. Install the K box and fasten it with 4 M12x20-8.8 flat head screws.
6. Tighten the 4 M12x20-8.8 flat head screws with a torque wrench; MA =
78 Nm.

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Energy Supply Systems A3 - A6 Specific customer version

Fig. 7-1: Installing the K box

1 Clamp 5 K box
2 Clip 6 Flat head screws
3 Cover, interface A3 7 Match plate
4 Flat head screws

7. Unscrew 7 Allen screws (3x M8, 4x M6) from the box clamp (captive
screws), open box clamp (>>> Fig. 7-2 ).
8. Open clamp, insert and align the dress package.
Insert and align the spring holder and clamping piece in the box clamp,
then close and lock the box clamp and the clamp.
9. Tighten 3 M8 Allen screws and 2 M6 Allen screws (captive screws).
10. Tighten the Allen screws with a torque wrench:
M6 MA = 7.5 Nm
M8 MA = 15 Nm
11. Connect all hose lines to interface A3 and tighten union nuts in accordance
with the warning sign.
12. Insert and lock all connectors of the electric cables at interface A3.
13. Connect all hose lines to interface A6 on the tool and tighten union nuts in
accordance with the warning sign.
If no tool is mounted, seal the supply lines pressure-tight with sealing
cones.
14. Insert and lock all connectors of the electric cables at interface A6.
15. Connect fluids to the hoses (hydraulic, compressed air, water or vacuum)
at the rated pressure.
16. Check hose lines for leaks, escaping fluids and flow noises.
17. Bundle the cables and secure them with Velcro.
18. Start up the robot and move axes 3 to 6 through their range of motion (T1
mode), checking for tension in the flexible tube, hoses and cables. For
preference, the motion throughout the workspace should be carried out
again using the corresponding application program in real time.
The hydraulic lines must be depressurized during motion of the robot.
19. If necessary, reposition the protector to adjust the springs.

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20. Shut down the robot and secure it.


21. Check the condition of all connections, cables and hoses and check for
leaks.
22. Check all cables and hoses for mechanical stress (tension, compression,
chafing, etc.).
23. Depressurize hose lines.
24. De-energize cables.
25. Mount the sliding cover, close it and lock it with an Allen screw. The sliding
cover is optional and is thus not always present.

Fig. 7-2: Installing dress package A3 - A6

1 Clamp 5 Clamping piece


2 Dress package 6 Protector
3 Spring holder 7 Allen screw
4 Box clamp 8 Sliding cover (optional)

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Specific customer version 8 Maintenance

8 Maintenance

8.1 Maintaining the energy supply system

Description If used for its intended purpose, the energy supply system requires minimal
maintenance, i.e. visual inspections are recommended. In certain operating
conditions, regular visual inspections may allow timely detection of changes.
This enables early detection of damage, thereby preventing failure of compo-
nents and assemblies. Exchange damaged components or assemblies.
A regular application-specific inspection is recommended for the following
components:
 Protectors
 Flexible tube
 Ball holder
 Hoses and cables

8.2 Cleaning the energy supply system

Description The energy supply system must be cleaned in compliance with the instructions
given here in order to prevent damage. These instructions only refer to the en-
ergy supply systems. System components, equipment and the controller must
be cleaned in accordance with the cleaning instructions relevant to them.
The following must be taken into consideration when using cleaning agents
and carrying out cleaning work:
 Only use solvent-free, water-soluble cleaning agents.
 Do not use flammable cleaning agents.
 Do not use aggressive cleaning agents.
 Do not use steam or refrigerants for cleaning.
 Do not use high-pressure cleaners.
 It must be ensured that no cleaning agent enters electrical or mechanical
system components.
 Do not contaminate or wash out the cable grease.
 Personnel protection measures must be taken.

Unintentional robot motions can cause injuries and dam-


age to property. If work is carried out on an operational
robot that is switched on, the robot can only be moved in T1 mode (reduced
velocity). It must be possible to stop the robot at any time by pressing an
EMERGENCY STOP switch. Operation must be limited to what is absolutely
necessary.
Warn all persons concerned before switching on and moving the robot.

Procedure 1. Shut down the system.


2. If necessary, stop adjacent system components and lock them.
3. Clean the energy supply system.
4. Fully remove all cleaning agents from the robot arm.
5. Clean any areas of corrosion and reapply corrosion protection.
6. Replace removed or missing cable grease.
7. Remove cleaning agents and cleaning equipment from the workspace of
the robot arm.
8. Dispose of cleaning agents properly.
9. Replace damaged and illegible plates and labels.

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10. Put only fully functional system components and systems back into oper-
ation.

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9 Repair

When installing components and assemblies, the fasten-


ing screws (standard, strength class 8.8) must be tight-
ened with the specified KUKA tightening torque. Exceptions to this will be
clearly marked.
The specified screw sizes and strength classes are those valid at the copy
deadline. The specifications contained in the Parts Catalog are, however, al-
ways to be taken as the most up-to-date information.
Screws of strength class 10.9 and higher may only be tightened once with the
rated tightening torque. When the screws are next slackened they must be
replaced with new ones.

9.1 Exchanging the energy supply system dress package

9.1.1 Removing dress package A3 - A6

Description The following describes the procedure for removing a dress package. The
contents and configuration of a dress package and the associated interfaces
are application-specific and may vary accordingly. The following description is
based on a random example, but applies analogously to all dress packages.

Unintentional robot motions can cause injuries and dam-


age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

When removing or installing the dress package, there is


a risk of crushing from pre-tensioned springs and hinged
clamps. Wearing protective gloves, carefully remove the dress package with
its pre-tensioned springs from the holders.

Preconditions  The robot is secured.


 The arm is positioned horizontally.
 Axes A4, A5 and A6 are as close as possible to the zero position.
 All assemblies and components are freely accessible.
 There is no hazard from other robots or system components.
 The power supply and pressure supply (e.g. water, air) to the energy sup-
ply system have been disconnected and secured against reconnection.
 Fluids (e.g. water, air) are in an uncritical temperature range.

Procedure for Depending on the configuration of the dress package, the following steps must
removal be carried out at interface A3 and interface A6 on the tool.
1. Open the clamp and remove the dress package from the clamp.
2. For each hose line, unscrew the union nuts and pull off the hose line
(>>> Fig. 9-1 ).
3. Release and unplug connectors of electric cables.
4. Unscrew the hexagon nut, remove the cable lug, lock washers and wash-
ers, and pull off the ground conductor.
5. If necessary, remove further cables and hoses and label to indicate the in-
stallation site.
6. Unscrew the lock screw, pull the sliding cover off backwards and set it
down.

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7. Unscrew 3 M8 Allen screws and 2 M6 Allen screws (captive Allen screws),


open box clamp and remove dress package.
8. Set the dress package down on a suitable support surface and catch and
dispose of any escaping fluids, e.g. water.
If the dress package is not to be reinstalled immediately, it must be pro-
tected against corrosion before being put into storage.

Fig. 9-1: Removing dress package A3 - A6

1 Clamp 6 Locking screw


2 Dress package 7 Interface A3
3 Box clamp 8 Hose lines
4 K box 9 Connector
5 Sliding cover

9. Seal all hoses and cables with sealing caps or similar.


10. Open all hinged clamps, remove the dress package and set it down on a
suitable support surface. Provide the dress package with sufficient support
during removal.

9.1.2 Installing the dress package

Description The following describes the procedure for installing a dress package. The con-
tents and configuration of a dress package and the associated interfaces are
application-specific and may vary accordingly. The following description is
based on a random example and applies analogously to all dress packages.

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Unintentional robot motions can cause injuries and dam-


age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

When removing or installing the dress package, there is


a risk of crushing from pre-tensioned springs and hinged
clamps. Wearing protective gloves, carefully remove the dress package with
its pre-tensioned springs from the holders.

Preconditions  The robot is secured.


 The arm is positioned horizontally.
 Axes A4, A5 and A6 are as close as possible to the zero position.
 All assemblies and components are freely accessible.
 There is no hazard from other robots or system components.
 The power supply and pressure supply (e.g. water, air) to the energy sup-
ply system have been disconnected and secured against reconnection.
Procedure for installation
1. Open the box clamp and the clamp .
2. Insert and align the dress package.
Insert and align the spring holder and clamping piece in the box clamp,
then close the box clamp and the clamp.
3. Tighten 3 M8 Allen screws and 2 M6 Allen screws (captive Allen screws).
4. Tighten the Allen screws with a torque wrench:
M6 MA = 7.5 Nm
M8 MA = 15 Nm
5. Connect all hose lines to interface A3 and tighten union nuts in accordance
with the warning sign.
6. Insert and lock all connectors of the electric cables at interface A3.
7. Connect all hose lines to interface A6 on the tool and tighten union nuts in
accordance with the warning sign.
If no tool is mounted, seal the supply lines pressure-tight with sealing
cones.
8. Insert and lock all connectors of the electric cables at interface A6 on the
tool.
9. Connect fluids to the hoses (hydraulic, compressed air, water or vacuum)
at the rated pressure.
10. Check hose lines for leaks, escaping fluids and flow noises.
11. Bundle the cables and secure them with Velcro.

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Fig. 9-2: Installing dress package A3 - A6

1 Clamp 6 Cover (optional)


2 Dress package 7 Clamping piece
3 Box clamp 8 Hose line
4 Springs 9 Plug
5 Allen screw

12. Start up the robot and move axes 3 to 6 through their range of motion (T1
mode), checking for tension in the flexible tube, hoses and cables. For
preference, the motion throughout the workspace should be carried out
again using the corresponding application program in real time.
The hydraulic lines must be depressurized during motion of the robot.
13. If necessary, reposition the protector to adjust the springs. If a new dress
package is installed, the installation position of the protectors can be taken
from the removed dress package. This reduces the time required for ad-
justment on the energy supply system.
Adjusting the dress package has a major influence on its service life. Great
care and intensive adjustment are rewarded by a longer service life. It may
be useful to modify or add to the programming to reduce the strain on the
energy supply system.
The standard position of the protectors is shown in the following figure.
(>>> Fig. 9-3 )

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Fig. 9-3: Standard adjustment of protectors A3 - A6

14. Shut down the robot and secure it.


15. Check the condition of all connections, cables and hoses and check for
leaks.
16. Check all cables and hoses for mechanical stress (tension, compression,
chafing, etc.).
17. Depressurize hose lines.
18. De-energize cables.
19. Mount the sliding cover, close it and lock it with an Allen screw. The cover
is optional and is thus not always present.

9.2 Exchanging the energy supply system holders

9.2.1 Removing the clamp

Description The following describes the procedure for removing a clamp. In the case of dif-
ferent clamps, proceed accordingly.

Unintentional robot motions can cause injuries and dam-


age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

Preconditions  The robot is secured.


 All assemblies and components are freely accessible.
 The dress package is not under tension. If necessary, move the tool to a
suitable position before commencing work in order to reduce strain on the
dress package.
 There is no hazard from other robots or system components.

Procedure for 1. Open the clamp and lift out the ball holder with dress package (>>> Fig. 9-
removal 4 ).
2. Remove 2 Allen screws with lock washers, and take off the clamp.

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Fig. 9-4: Removing the clamp

1 Allen screw with lock washer 3 Flexible tube


2 Clamp 4 Ball holder

9.2.2 Installing the clamp

Description The following describes the procedure for installing a clamp.

Unintentional robot motions can cause injuries and dam-


age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

Preconditions  The robot is secured.


 All assemblies and components are freely accessible.
 The dress package is installed without tension. If necessary, move the tool
to a suitable position before commencing work in order to reduce strain on
the dress package.
 There is no hazard from other robots or system components.

Procedure for 1. Coat the thread of the Allen screws with Drei Bond 1342 locking agent be-
installation fore inserting them.
2. Mount clamp on the holder and fasten it with 2 M8x16-8.8 Allen screws
and lock washers (>>> Fig. 9-5 ).
3. Tighten the Allen screws with a torque wrench; MA = 15 Nm.
4. Open the clamp, insert the dress package with ball holder, and align the
clamping piece so that it fits correctly in the apertures of the clamp.
5. Close and lock the clamp.

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Fig. 9-5: Installing the clamp

1 Allen screw with lock washer 3 Holder


2 Clamp 4 Ball holder

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Specific customer version 10 Decommissioning, storage and disposal

10 Decommissioning, storage and disposal

10.1 Removing energy supply system A3 - A6

Description The following describes the procedure for removing an energy supply system
A3 - A6. The contents and configuration of a dress package and the associat-
ed interfaces are application-specific and may vary accordingly. The following
description is based on a random example, but applies analogously to all en-
ergy supply systems A3 - A6.

Unintentional robot motions can cause injuries and dam-


age to property. If work is carried out on an operational
robot, the robot must be secured by activating the EMERGENCY STOP de-
vice.
Warn all persons concerned before starting to put it back into operation.

When removing or installing the dress package, there is


a risk of crushing from pre-tensioned springs and hinged
clamps. Wearing protective gloves, carefully remove the dress package with
its pre-tensioned springs from the holders.

Preconditions  The robot is secured.


 The arm is positioned horizontally.
 Axes A4, A5 and A6 are as close as possible to the zero position.
 All assemblies and components are freely accessible.
 There is no hazard from other robots or system components.
 The power supply and pressure supply (e.g. water, air) to the energy sup-
ply system have been disconnected, depressurized and secured against
reconnection.
 Fluids (e.g. water, air) are in an uncritical temperature range.

Procedure for Depending on the configuration of the dress package, the following steps must
removal be carried out at interface A3 and interface A6 on the tool.
1. Open the clamp and remove the dress package from the clamp
(>>> Fig. 9-1 ).
2. For each hose line, unscrew the union nuts and pull off the hose line.
3. Release and unplug connectors of electric cables.
4. Unscrew the hexagon nut, remove the cable lug, lock washers and wash-
ers, and pull off the ground conductor.
5. If necessary, remove further cables and hoses and label to indicate the in-
stallation site.
6. Unscrew the lock screw, pull the sliding cover off backwards and set it
down.
7. Unscrew 3 M8 Allen screws and 2 M6 Allen screws (captive Allen screws),
open box clamp and remove dress package.
8. Set the dress package down on a suitable support surface and catch and
dispose of any escaping fluids, e.g. water.
9. Seal all hoses and cables with sealing caps or similar.
10. Open all hinged clamps, remove the dress package and set it down on a
suitable support surface. Provide the dress package with sufficient support
during removal.

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Fig. 10-1: Installing dress package A3 - A6

1 Clamp 5 Clamping piece


2 Dress package 6 K box
3 Spring holder 7 Locking screw
4 Box clamp 8 Sliding cover

11. Loosen the fastening screws of the clamp and remove the clamp
(>>> Fig. 10-2 ).
12. Loosen the fastening screws of the clips and remove the clips.
13. Unscrew 4 flat head screws and take off K box.
14. Unscrew 4 flat head screws and take off match plate with cover of interface
A3.

Fig. 10-2: Removing the K box

1 Clamp 5 K box
2 Clip 6 Flat head screws
3 Cover, interface A3 7 Match plate
4 Flat head screws

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15. If the energy supply system is not to be reinstalled, it must be protected


against corrosion before being put into storage.

10.2 Storage

Description If the energy supply system is to be put into long-term storage, the following
points must be observed:
 The place of storage must be as dry and dust-free as possible.
 Avoid temperature fluctuations.
 Avoid wind and drafts.
 Avoid condensation.
 Use appropriate coverings that cannot detach themselves and which can
withstand the expected environmental conditions.
 Do not leave any loose parts on the energy supply system, especially ones
that might knock against other parts; either remove or fasten accordingly.
 Do not leave the energy supply system exposed to direct sunlight while in
storage.
 Observe and comply with the permissible temperature ranges for storage.
 Select a storage location in which the packaging materials cannot be dam-
aged.
 In the case of longer-term storage, check the energy supply system.

Procedure 1. Remove the energy supply system.


2. Clean and dry the energy supply system. No dirt or cleaning agent residue
may remain on or in the energy supply system.
3. Visually inspect the energy supply system.
4. Remove any foreign bodies.
5. Remove any corrosion and damage.
6. Drain all fluids from the hose lines.
7. Attach all covers to the hoses and cables and check that the seals are cor-
rectly in place.
8. Seal off electrical connections with suitable covers.
9. Seal hose connections by suitable means.
10. Cover the energy supply system with plastic film and seal it against dust.
If necessary, add a desiccant beneath the sheeting.
11. Package any individual parts and secure them in the transport container.

10.3 Disposal

When the energy supply system reaches the end of its useful life, it can be re-
moved from the system and dismantled, and the materials can be disposed of
properly by type.
The following table provides an overview of the materials used in the energy
supply system. All plastic components are marked with a material designation
and must be disposed of accordingly.

Material, desig- Subassembly, component Note


nation
PAG-GF Covers Sort before disposal
Steel Bearings, holders, inter- Sort before disposal
face plates, springs,
screws and washers

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Material, desig- Subassembly, component Note


nation
Cable grease Flexible tube See safety data sheet,
RB1 consumables
(>>> 11.1.1 "Safety data
sheet for Optitemp RB1
cable grease" Page 45)
Copper Electric cables Sort and recycle
Glass fiber Fiber-optic cables Dispose of as household
refuse
PU Hose lines Sort before disposal
Brass Screwed fittings Sort before disposal
PA Hinged clamps and pro- Sort before disposal
tectors
PA, PU Flexible tube Sort before disposal
EPDM, TPE Clamping piece Sort before disposal
POM Sliding elements Sort before disposal

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Specific customer version 11 Appendix

11 Appendix

11.1 Safety data sheets

11.1.1 Safety data sheet for Optitemp RB1 cable grease

The following extract from the safety data sheet according to 91/155/EEC
must be observed.

11.1.1.1 Designation of substance/formulation and manufacturer

Name of substance/preparation
Trade name: Optitemp RB1
SDS no.: 455577
Use: Lubricant

Manufacturer designation
Company: Deutsche BP Aktiengesellschaft, Industrial Lubricants &
Services
Address: Erkelenzer Strasse 20, D-41179 Mönchengladbach
Country: Germany
Tel.: +49 (0)2161 909-319
Fax: +49 (0)2161 909-392
Emergency hotline: Carechem: +44 (0)208 762 8322
e-mail address: MSDSadvice@bp.com

11.1.1.2 Composition / Information about the components

Chemical characterization: Synthetic lubricant and additives. Thickeners.

Hazardous components: This product contains no dangerous components above the


legally defined limit values.

11.1.1.3 Possible hazards

The preparation is NOT classified as hazardous in accordance with Directive


1999/45/EC in its altered and adapted version.

Physical / chemical hazards: Not classified as dangerous.


Human health hazards: May irritate eyes and skin.
Environmental hazards: Unlikely to be harmful to aquatic organisms.

Effects and symptoms


Eyes: May cause mild eye irritation.
Skin: Can dry out the skin and lead to irritation and/or dermatitis.
Allergic reactions are possible in the worst case.
Inhalation: Inhalation of oil mist or vapors at elevated temperatures may
cause respiratory irritation.
Ingestion: Ingestion may cause gastrointestinal irritation (e.g. diarrhea).

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11.1.1.4 First aid measures

Contact with eyes: Rinse eyes immediately with plenty of water for several min-
utes. If irritation occurs, consult a doctor.
Skin contact: Wash affected areas of skin with soap and water, or use suit-
able cleaning agent. Change clothing and shoes if they become
contaminated with product. Wash clothing before reuse. Clean
shoes thoroughly before reuse. If irritation occurs consult a doc-
tor.
Inhalation: Take affected person into fresh air. Consult a doctor if symp-
toms persist.
Ingestion: Do not induce vomiting. If the person is unconscious, do not
give anything by mouth. Consult a physician immediately.
Notes to physician: Treatment should in general be symptomic and directed at
relieving any effects.
Note regarding high-pressure applications.
Injection into the skin due to contact with a product under high
pressure constitutes a major medical emergency. Within a few
hours the tissue swells up and becomes discolored and
extremely painful, with severe subcutaneous necrosis.
Surgical treatment is absolutely imperative. Comprehensive
opening of the wound and the tissue beneath it is necessary in
order to reduce tissue loss and to prevent or limit lasting dam-
age. The high pressure can cause the product to penetrate
extensive areas of tissue layers.

11.1.1.5 Fire-fighting measures

Suitable extinguishing agents: In the event of a fire: use water spray (mist), foam, dry chemi-
cals or CO2.
Unsuitable extinguishing Do not use water jets.
agents:
Special instructions for extin- Contaminated extinguishing water must be collected separately
guishing work: and prevented from entering the drainage system.
Hazardous decomposition Decomposition products include various oxides (e.g. carbon
products: oxides).
Unusual fire/explosion haz- This product is not inherently explosive in accordance with the
ards: applicable rules.
Special fire-fighting measures: -
Protection of fire-fighters: Fire-fighters must wear self-contained positive pressure breath-
ing apparatus (SCBA) and full protective gear.

11.1.1.6 Measures after unintended release

Personal safety precau- In case of spillage, isolate the hazard area. Avoid contact with
tions: the hazardous substance and avoid inhaling vapors. Ensure
adequate ventilation. Where there is insufficient ventilation,
wear suitable respiratory equipment. Use suitable protective
equipment.
Environmental protection Prevent the product from entering the drainage system, surface
measures: waters and soil. Notify the competent authorities, if required.

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Large spills: Stop the leak if you can do so without risk. Remove container
from spill area. Flush spilled material into a wastewater treat-
ment plant. Contain spilled material using a non-combustible
absorbent (e.g. sand, soil, vermiculite, diatomaceous earth) and
collect in the containers provided. Disposal should be entrusted
to a recognized waste disposal company. Contaminated absor-
bents can be just as dangerous.
Small spills: Stop the leak if you can do so without risk. Remove container
from spill area. Dilute with water and mop up, or add absorbent
material and place the substance in a suitable container for dis-
posal. Disposal should be entrusted to a recognized waste dis-
posal company.

11.1.1.7 Handling and storage

Handling: Prevent contact with skin or clothing. Spilled and leaked product
must be prevented from coming into contact with soil and sur-
face waters. Wash thoroughly after handling.
Storage: Keep containers tightly sealed. Keep containers in a cool, well-
ventilated area.
Unsuitable: Avoid prolonged exposure to increased temperatures.

VCI storage class: 11

11.1.1.8 Exposure limits and personal protective equipment

Threshold limit values No occupational exposure threshold limit values have been
(TLV): assigned for this product.

Protective measures
Limitation and monitoring of Provide exhaust ventilation or other engineering controls.
exposure in the workplace:
Hygiene measures: Wash hands, forearms and face thoroughly after handling
chemical products.
Respiratory protection: Sufficient ventilation is recommended in industry. If ventilation is
insufficient, respiratory protection is useful.
Hand protection: Wear chemical-resistant gloves (recommended: nitrile gloves) if
prolonged or repeated contact is likely.
Eye protection: Protective goggles with side shields to guard against splashing.
Skin and body: Wear appropriate clothing to avoid prolonged skin contact.

11.1.1.9 Physical and chemical properties

Physical state: Paste


Color: Light beige
Odor: Slight
Flash point: Closed cup: >150 °C
Vapor pressure: <0.01 kPa (<0.075 mm Hg) at 20 °C
Penetration number (0.1 mm) 280 at 25 °C
Melting point/range: 192 °C
Drop point: >180 °C

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Density: <1000 kg/m3 (<1 g/cm3) at 20 °C


Solubility: Insoluble in water

11.1.1.10Stability and reactivity

Incompatible with various sub- Reactive or incompatible with oxidizing materials.


stances:
Hazardous polymerization: The product is stable. No hazardous polymerization occurs
under normal conditions.
Hazardous decomposition Decomposition products may include various oxides (e.g. car-
products: bon oxides). No hazardous decomposition products should be
formed under normal conditions of storage and use.

11.1.1.11Toxicological information

Chronic effects: No particular effects or risks known.


Effects on eyes: May cause mild eye irritation.
Effects on skin: Prolonged or repeated contact can dry out the skin and lead to
irritation and/or dermatitis. Allergic reactions are possible in the
worst case.
Effect if inhaled: Vapors and aerosols may cause irritation of the mucous mem-
branes of the nose and throat.
Effect if ingested: May cause nausea, vomiting and diarrhea.

11.1.1.12Ecological information

Persistence / degradability: Biodegradable.


Mobility: The product is non-volatile. Insoluble in water.
Environmental hazards: Not classified as dangerous.

11.1.1.13Disposal information

Disposal information
Disposal information / waste Spilled and leaked product must be prevented from coming into
specifications: contact with soil and surface waters. Observe local, regional
and national regulations. Use only approved transporters, recy-
clers, treatment, storage or disposal facilities. If necessary, dis-
posal should be entrusted to a recognized waste disposal
company.

Unused product
European Waste Catalog Waste code 12 01 12*: Used waxes and greases
(EWC):

Packaging
European Waste Catalog Waste code 15 01 10*: Packaging containing the residue of
(EWC): hazardous materials or contaminated by hazardous materials.

Use of the product for purposes other than those specified and/or impurities
can necessitate the use of a different waste code number for the waste pro-
ducer.

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Hazardous waste
On the basis of the supplier’s current state of knowledge, this product is not considered as haz-
ardous waste as defined by EU directive 91/689/EC.

11.1.1.14Transport information

Classification: Not hazardous as defined by the transport regulations (ADR/


RID, ADNR, IMDG, ICAO/IATA).

11.1.1.15Regulations

EU regulations: EC Directives 1999/45/EC and 67/548/EEC.

Labeling requirements
Risk (R) phrases: This product is not classified according to the Dangerous Sub-
stances Order / EU regulations.
Additional warning labels: Contains acetic acid, (4-nonylphenoxyl). Can cause allergic
reactions.

Miscellaneous provisions
Inventories: European inventory: All components are listed or exempted.
US inventory (TSCA 8b): All components are listed or
exempted.
Australian inventory (AICS): At least one component is not
listed.
Canadian inventory: At least one component is not listed.
Inventory of Existing Chemical Substances in China
(IECSC): At least one component is not listed.
Japanese inventory of Existing and New Chemical Sub-
stances (ENCS): At least one component is not listed.
Korean Existing Chemicals Inventory (KECI): All compo-
nents are listed or exempted.
Philippine Inventory of Chemicals and Chemical Sub-
stances (PICCS): All components are listed or exempted.
Classification acc. to the Ger- 1, Annex no. 4
man Administrative Regula-
tion on the Classification of
Substances Hazardous to
Water into Water Hazard
Classes (VwVwS):

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11.1.1.16Other information

Notes for the reader


All information is based on the current state of our knowledge. It is intended only to describe our
product with regard to the safety data. It is not intended to provide assurance of particular proper-
ties.
The product may only be used for the scope of work specified above; any other use requires prior
consultation with KUKA. Using the product for any purpose other than for its designated use
could lead to risks which are not described in this document.
Further information on the use of the product may be found in the relevant technical specifica-
tions.

11.1.2 Safety data sheet for universal adhesive and sealant type 1342

The following extract from the safety data sheet according to 1907/2006/EEC
must be observed.

11.1.2.1 Designation of substance and manufacturer

Substance name
Product name: DREI BOND / THREE BOND type 1342
Use of substance: Adhesive and sealant

Manufacturer designation
Company: Drei Bond GmbH
Address: Carl-Zeiss-Ring 17, D-85737 Ismaning
Country: Germany
Tel.: +49 (0)89 96 24 27-0
Fax: +49 (0)89 96 24 27 19
Emergency hotline: +49 (0)89 41 40 22 11

11.1.2.2 Possible hazards

R36/37/38: Irritating to eyes, respiratory system and skin.


R43: May cause sensitization by skin contact.

11.1.2.3 Composition / Information about the components

Chemical description CAS no. % EINECS Classification


Methacrylate ester UE N.607- > 10% Xi = irritant,
134.00.4 R36/37/38
Hydroxyethyl methacrylate 868-77-9 1 - < 20% 212-782-2 Xi = irritant,
R36/38, R43
Hydroxypropyl methacrylate 27813-02-1 1 - < 20% 248-666-3 Xi = irritant,
R36, R43
Cumene hydroperoxide 80-15-9 1% 201-254-7 O, T, N, R7,
R21/22, R23,
R34, R48/20/
22, R51/53

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11.1.2.4 First aid measures

After contact with eyes: In case of contact, rinse eyes immediately with plenty of water
for at least 10 to 15 minutes and consult a physician.
After skin contact: Wipe off with a cloth or paper towel and wash immediately with
plenty of soap and water.
After inhalation: Ensure plenty of fresh air.
After swallowing: Do not induce vomiting. Rinse mouth, drink plenty of water and
consult a physician.

11.1.2.5 Fire-fighting measures

Suitable extinguishing agents: Foam, dry powder, sand.


Specific hazards: Vapors may form a toxic mixture in contact with oxygen.
Special protective equipment: Respiratory protection and protective clothing.
Additional instructions: Cool containers with water mist.

11.1.2.6 Measures after unintended release

Personal safety precau- Avoid contact with eyes and skin.


tions:
Environmental protection Observe local authority regulations.
measures:
Cleaning: Bind with an absorbent material such as sand or granulate and
dispose of in accordance with the regulations.

11.1.2.7 Handling and storage

Instructions on safe han- Ensure adequate ventilation.


dling:
Instructions relating to fire Observe general fire protection regulations.
and explosion protection:
Storage: Keep containers in a cool, dry area (long-term storage not
above 28 °C). Keep containers tightly sealed.

11.1.2.8 Exposure limits and personal protective equipment

Protective measures
Personal protective equip- If using product over a longer period, wear suitable protective
ment: clothing.
Hygiene measures: Avoid contact with skin and eyes.
Respiratory protection: Use only in well ventilated areas.
Hand protection: In case of prolonged skin contact, wear protective gloves, e.g.
made of PE.
Eye protection: If using product over a longer period, wear safety goggles.

11.1.2.9 Physical and chemical data

General information / appearance


Physical state: Liquid.
Color: Blue.

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General information / appearance


Odor: Hydrocarbon odor.
Viscosity at 25° C: 150 mPa.s.
Vapor pressure (at 20 °C): >3.0 mbar.
pH value: <7.

Important information on health and environmental protection and on safety


Flash point: >100°C.
Density acc. to DIN 51757: approx. 1.02 g/cm3.
Temperature resistance: -50 to 150 °C.

11.1.2.10Storage stability and reactivity

Stability: The product is stable under normal conditions.


Conditions to be avoided: Avoid storage above 40 °C and exposure to direct sunlight.
Materials to avoid: Strong oxidizing substances.
Hazardous decomposition Under combustion conditions, oxides of carbon are released in
products: small quantities.

11.1.2.11Toxicological information

Effects
Eyes: Irritant.
Skin: Irritant.
Sensitization: Possible in the event of prolonged skin contact.
Inhalation: Irritant.
Acute toxicity: LD 50 oral > 5,000 mg/kg (rat).

11.1.2.12Ecological information

Environmental hazards: Prevent from entering wastewater disposal systems.

Disposal information
Recommendation: Dispose of as hazardous waste in accordance with the regula-
tions. Small quantities may be disposed of in domestic waste
incineration plants.
Observe local authority regulations.

Unused product
European waste code no.: 08 04 00

11.1.2.13Transport information

Transportation by land: ADR/GGVS: Not hazardous.


RID/GGVE: Not hazardous.
Transportation by sea: IMDG: Not hazardous.
Air freight: ICAO/IATA: Not hazardous.

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11.1.2.14Labeling

Labeling requirements
Risk (R) phrases: R36/37/38: Irritating to eyes, respiratory system and skin.
R43: May cause sensitization by skin contact.
Safety (S) phrases: S24/25: Avoid contact with skin and eyes.
S26: In case of contact with eyes, rinse immediately with plenty
of water and seek medical advice.
S28: After contact with skin, wash immediately with plenty of
soap and water.
S37/39: Wear suitable gloves and eye/face protection.
Xi: Irritant.
Additional warnings: Contains methacrylate ester and hydroxypropyl/hydroxyethyl
methacrylates.

Miscellaneous provisions
Water hazard classification 1 (manufacturer’s classification) insoluble in water.
(WGK):

11.1.2.15Other information

Full text of R-phrases referred R21/22: Harmful in contact with skin and if swallowed.
to by number in Section
R23: Toxic by inhalation.
(>>> 11.1.2.14 "Labeling"
Page 53). R34: Causes burns.
R36: Irritating to eyes.
R36/37/38: Irritating to eyes, respiratory system and skin.
R36/38: Irritating to eyes and skin.
R43: May cause sensitization by skin contact.
R48/20/22: Danger of serious damage to health by prolonged
exposure, harmful by inhalation and if swallowed.
R51/53: Toxic to aquatic organisms, may cause long-term
adverse effects in the aquatic environment.
R7: May cause fire.

Notes for the reader


This information is based on our current state of knowledge and experience; no responsibility is
accepted for its reliability, completeness or freedom from error. The information does not repre-
sent any assurance of product characteristics, and does not establish a legally valid contractual
relationship.
The users of our products are solely responsible for observing the applicable legislation and reg-
ulations. The information provided may no longer apply if the product is used together with other
materials or in a manufacturing process. (Date of issue: 03/2010)

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Specific customer version 12 KUKA Service

12 KUKA Service

12.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.

Information The following information is required for processing a support request:


 Model and serial number of the robot
 Model and serial number of the controller
 Model and serial number of the linear unit (if applicable)
 Model and serial number of the energy supply system (if applicable)
 Version of the KUKA System Software
 Optional software or modifications
 Archive of the software
For KUKA System Software V8: instead of a conventional archive, gener-
ate the special data package for fault analysis (via KrcDiag).
 Application used
 Any external axes used
 Description of the problem, duration and frequency of the fault

12.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)


Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com

Australia Headland Machinery Pty. Ltd.


Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
vic@headland.com.au
www.headland.com.au

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Belgium KUKA Automatisering + Robots N.V.


Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.


Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br

Chile Robotec S.A. (Agency)


Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl

China KUKA Robotics China Co.,Ltd.


Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1888
Fax +86 21 6787-1803
www.kuka-robotics.cn

Germany KUKA Roboter GmbH


Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de

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France KUKA Automatisme + Robotique SAS


Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr

India KUKA Robotics India Pvt. Ltd.


Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
info@kuka.in
www.kuka.in

Italy KUKA Roboter Italia S.p.A.


Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it

Japan KUKA Robotics Japan K.K.


Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
info@kuka.co.jp

Korea KUKA Robotics Korea Co. Ltd.


RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com

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Malaysia KUKA Robot Automation Sdn Bhd


South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my

Mexico KUKA de Mexico S. de R.L. de C.V.


Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx

Norway KUKA Sveiseanlegg + Roboter


Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
info@kuka.no

Austria KUKA Roboter Austria GmbH


Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at

Poland KUKA Roboter Austria GmbH


Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de

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Portugal KUKA Sistemas de Automatización S.A.


Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt

Russia OOO KUKA Robotics Rus


Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar AB


A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se

Switzerland KUKA Roboter Schweiz AG


Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

Spain KUKA Robots IBÉRICA, S.A.


Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
Comercial@kuka-e.com
www.kuka-e.com

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South Africa Jendamark Automation LTD (Agency)


76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan KUKA Robot Automation Taiwan Co., Ltd.


No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
info@kuka.com.tw
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd


Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH


Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz

Hungary KUKA Robotics Hungaria Kft.


Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

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USA KUKA Robotics Corp.


22500 Key Drive
Clinton Township
48036
Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com

UK KUKA Automation + Robotics


Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk

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Specific customer version Index

Index
Numbers P
2004/108/EC 23 Personnel protection 31
2006/95/EC 23 Product description 9
Purpose 7
A
Adhesive and sealant, universal type 1342 50 R
Ambient temperature, operation 13 Recommissioning 27
Ambient temperature, storage 13 Relative air humidity 13
Ambient temperature, transportation 13 Repair 33
Appendix 45
Applied norms and regulations 23 S
Safety 23
C Safety data sheet for universal adhesive and
Cable grease, Optitemp RB1 45 sealant type 1342 50
Clamp, installing 38 Safety data sheet, Optitemp RB1 cable grease
Clamp, removing 37 45
Cleaning 31 Safety data sheets 45
Cleaning agents 31 Safety instructions 5
Safety of machinery 23
D Service, KUKA Roboter 55
Description, dress package A3 - A6 10 Start-up 27
Description, fastening materials, A3 - A6 11 Steam, refrigerants 31
DIN EN 60204-1 23 Support request 55
DIN EN 61000-6-2 23
DIN EN 61000-6-4 23 T
Disposal 43 Technical data 13
Documentation, options 5 Training 7
Dress package, installing 34 Transportation 25
Dress package, removing 33 Transportation of assemblies and components
25
E
Electromagnetic compatibility (EMC) 23 U
EMC Directive 23 Universal adhesive and sealant type 1342 50
Energy supply system dress package, ex- Users 7
changing 33
Energy supply system holders, exchanging 37 W
Energy supply system, cleaning 31 Warnings 5
Energy supply system, maintenance 31

H
Humidity rating 13

I
Intended use 7
Introduction 5

K
KUKA Customer Support 55

L
Low Voltage Directive 23

M
Maintenance 31
Material designation 43

O
Optitemp RB1, cable grease 45

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