Professional Documents
Culture Documents
EnergySupply A1 A3 Welding HN 255 642
EnergySupply A1 A3 Welding HN 255 642
EnergySupply A1 A3 Welding HN 255 642
KR QUANTEC
Art. no. 00-255-642, 00-255-643
Assembly and Operating Instructions
Energy Sup-
ply System A1
- A3
Issued: 25.02.2015
© Copyright 2015
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
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
5 Safety ............................................................................................................ 25
5.1 Safety of the option .................................................................................................... 25
Index ............................................................................................................. 35
1 Introduction
t
Hints These notices serve to make your work easier or contain references to further
information.
2 Purpose
2
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of mechanical engineering
Advanced knowledge of electrical and electronic systems
Knowledge of the robot controller system
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 misuse
and is not allowed. This includes e.g.:
Operation with non-specified fluids
Operation outside the permissible operating parameters
Use in potentially explosive environments
Use in underground mining
Use with unauthorized robot systems
3 Product description
3.1
t
Description of energy supply system A1 - A3
This description applies to all standard robots of the QUANTEC product se-
s
Overview
ries. Different reaches have no effect on the structure and function of the en-
ergy supply system.
The energy supply system consists of the following principal components:
Dress package
Interface A1
Interface A3
Fastening materials
For use in certain production technologies, the robot can be equipped with an
energy supply system (>>> Fig. 3-1 ) between the base frame (axis 1) and the
arm (axis 3). An energy supply system consists of a dress package for trans-
mitting the energy, fluids and signals typical of the technological process con-
cerned, and the “fastening materials” assembly required for attaching it to the
robot. The energy supply system A1 - A3 is installed between interface A1 on
the base frame and interface A3 on the arm and consists of an application-
specific dress package with a flexible tube. The flexible tube is attached to the
robot in such a way that it is fixed at the rotating column and free to rotate on
the arm, and is routed via the link arm to interface A3 on the arm. The supply
lines of the dress package are routed through the center of the gear unit of ax-
is 1.
The compact unit can be quickly exchanged without great effort. It is attached
to the robot in such a way that the dress package does not hinder the motion
of the robot, but has maximum freedom of movement with minimum wear and
maximum protection.
Dress package The contents of the dress package (>>> Fig. 3-2 ) depend on the specific ap-
plication and may therefore vary greatly. At the two extremes, the dress pack-
age can either be empty, or filled to a maximum of 70% of the cross-sectional
area of the flexible tube. The following figure shows the composition for this
energy supply system.
The axis 1 interface is located on the base frame. From the interface, the ca-
bles and hoses are routed via a hinged clamp through gear unit A1 to the
clamping piece where they are fixed in place and aligned. From here, the ca-
bles and hoses are routed in the flexible tube around the rotating column,
along the link arm, to interface A3 on the arm. At the end of the flexible tube is
a clamping piece for locating and orienting the cables and hoses. At interface
A3, the cables are fastened by means of connector housings and the hoses
by means of bulkhead unions.
The clamping piece and cable stars 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 piece are determined by the composition of the
dress package.
The flexible tube consists of the corrugated tube, support shells, intermediate
pieces, fasteners and other components. The intermediate pieces are used for
fixing the flexible tube in the hinged clamps in such a way that it can rotate
freely. The position of the intermediate pieces is indicated by white markings
on the flexible tube.
Further information and detailed specifications about this assembly can be
found in the parts catalog and Chapter (>>> 4 "Technical data" Page 15).
Interface A1 The cables and hoses of the energy supply system are connected to the robot
via interface A1 (>>> Fig. 3-3 ), which is located in the base frame of the ro-
bot. All incoming cables and hoses from the system are connected to the robot
here. The interface is application and task-specific and has either connectors
or unions, depending on the equipment. Coded connectors and labeling of the
connections prevent incorrect configuration of the interface.
Further information and detailed specifications about this interface can be
found in the parts catalog and Chapter (>>> 4 "Technical data" Page 15).
Interface A3 “Energy supply system A3 - A6” is connected via interface A3 (>>> Fig. 3-4 ),
which is located on the arm of the robot. All incoming cables and hoses from
“Energy supply system A1 - A3” are connected here. The interface is applica-
tion and task-specific and has either connectors or unions, depending on the
equipment. Coded connectors and labeling of the connections prevent incor-
rect configuration of the interface.
Further information and detailed specifications about this interface can be
found in the parts catalog and Chapter (>>> 4 "Technical data" Page 15).
Fastening The “fastening materials” assembly contains all parts required for fastening
materials, A1 - A3 the dress package and interfaces A1 and A3 to the base frame, rotating col-
umn and arm. This assembly also contains the fastening materials for con-
necting the cables and hoses to the interfaces. Since the configuration of the
energy supply system is always application-specific, the contents and scope
of the fastening materials are also tailored to the specific dress package.
4 Technical data
4
t
Thermal and electrical overloading of multi-strand cables
can damage the energy supply system. Observe and
comply with EN 60204-1.
4.2 Interface A1
1 Motor cable for single axis, XM7.1, power coupling, 6-pole, E-part
2 Interbus cable, XGUN1,
bus coupling, SpeedTEC-ready, 19-pole, E-part
3 Welding cable, X73, pin housing RobiFix S 35 MTB
4 Water line, M22x1.5 bulkhead union
5 Water line, M22x1.5 bulkhead union
6 Air line, M22x1.5 bulkhead union
7 Control cable for single axis, X7, Molex connector, 8-pole to RDC
8 Profinet cable, XPN1, coupling, round, HAN Push Pull RJ45
9 Power supply, XPP1, coupling, HAN Push Pull L Power
4.3 Interface A3
Information about the configuration and contents of the dress package is given
in Chapter (>>> 3 "Product description" Page 9). Detailed specifications for
the supply lines contained in the dress package can be found in the following
sections.
ID no. 003.45-01
Configuration 1x 35 mm2, GNYE
2x 35 mm2, BK
Rated voltage 600 V AC
Current EN 60204-1 (derating factors must be taken into
account)
ID no. 012.09-01
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 A1 Bus coupling, SpeedTEC-ready, 19-pole
Connection A3 Bus coupling, SpeedTEC-ready, 19-pole
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected
ID no. 024.22-01
Configuration 2x (2x AWG22), shielded
Rated voltage 30 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A1 Coupling, round, Han Push Pull RJ45
Connection A3 Coupling, round, Han Push Pull RJ45
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected
ID no. 015.12-01
Configuration 5x 1.5 mm2
Overall braided shield
Rated voltage 24 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A1 HAN PushPull L Power coupling
Connection A3 HAN PushPull L Power coupling
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected
ID no. 030.02-01
Configuration 4x (2x 0.25 mm2), shielded in pairs
Rated voltage 160 V AC/DC
Current EN 60204-1 (derating factors must be taken into
account)
Connection A1 Molex connector, 8-pole to RDC
Connection A3 Signal coupling/female, 12-pole, E-part on arm
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected
ID no. 010.39-01
Configuration 4x 2.5 mm2 + 2x 1 mm2, overall shield
Rated voltage EN 60204-1 (derating factor must be taken into
account)
Current EN 60204-1 (derating factor must be taken into
account)
Connection A1 Power coupling, 6-pole, E-part
Connection A3 Circular power connector, 6-pole, P-part
Minimum bending 10x outer diameter
radius
Protection class IP65
when connected
ID no. 533.01-01
Hose line Hose 1/2", blue
Connection A1 Bulkhead union, straight, M22x1.5
Connection A3 Bulkhead union, straight, M22x1.5
Rated pressure max. 1.6 MPa (16 bar)
Hose length See parts catalog
Minimum bending 70 mm
radius
Permissible thermal 243 K to 353 K (-30 °C to +80 °C)
loading
ID no. 531.01-01
Hose line Hose 1/2", green
Connection A1 Bulkhead union, straight, M22x1.5
Connection A3 Bulkhead union, straight, M22x1.5
Rated pressure max. 1.6 MPa (16 bar)
ID no. 532.01-01
Hose line Hose 1/2", red
Connection A1 Bulkhead union, straight, M22x1.5
Connection A3 Bulkhead union, straight, M22x1.5
Rated pressure max. 1.6 MPa (16 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
5 Safety
f
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.
6 KUKA Service
A
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Index
A
Air line, blue 22
Ambient temperature, operation 15
Ambient temperature, storage 15
Ambient temperature, transportation 15
D
Description, energy supply system A1 - A3 9
Description, fastening materials A1 - A3 13
Documentation, options 5
H
Humidity rating 15
I
Intended use 7
Interface A1 11
Interface A3 12
Introduction 5
K
KUKA Customer Support 27
P
Product description 9
Purpose 7
R
Relative air humidity 15
S
Safety 25
Safety instructions 5
Safety, option 25
Service, KUKA Roboter 27
Support request 27
T
Technical data 15
Training 7
U
Users 7
W
Warnings 5
Welding cable 16