Spez KR AGILUS-2 en

Robots
KR AGILUS-2
Specification
Issued: 07.12.2020
Spez KR AGILUS-2 V5
KUKA Deutschland GmbH
KR AGILUS-2
© Copyright 2020
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 Spez KR AGILUS-2 (PDF) en

PB10511
Book structure: Spez KR AGILUS-2 V2.1

BS9717
Version: Spez KR AGILUS-2 V5
2/131 | www.kuka.com Spez KR AGILUS-2 V5 | Issued: 07.12.2020

KR AGILUS-2
Contents
1 Introduction.............................................................................................. 5
1.1 Target group.......................................................................................................... 5
1.2 Industrial robot documentation.............................................................................. 5
1.3 Representation of warnings and notes................................................................. 5
1.4 Terms used............................................................................................................ 6
2 Product description................................................................................. 9
2.1 Overview of the robot system............................................................................... 9
2.2 Description of the manipulator.............................................................................. 10
2.3 Intended use and misuse...................................................................................... 11
3 Safety......................................................................................................... 13
3.1 General.................................................................................................................. 13
3.1.1 Disclaimer.............................................................................................................. 13
3.1.2 EC declaration of conformity and declaration of incorporation............................ 14
3.1.3 Terms in the “Safety” chapter............................................................................... 14
3.2 Personnel............................................................................................................... 16
3.3 Workspace, safety zone and danger zone........................................................... 17
3.4 Overview of protective equipment........................................................................ 17
3.4.1 Mechanical end stops........................................................................................... 18
3.4.2 Mechanical axis limitation (optional)..................................................................... 18
3.4.3 Options for moving the manipulator without drive energy................................... 18
3.4.4 Labeling on the industrial robot............................................................................ 19
3.5 Safety measures.................................................................................................... 19
3.5.1 General safety measures...................................................................................... 19
3.5.2 Transportation........................................................................................................ 21
3.5.3 Start-up and recommissioning.............................................................................. 21
3.5.4 Manual mode......................................................................................................... 23
3.5.5 Automatic mode..................................................................................................... 24
3.5.6 Maintenance and repair........................................................................................ 24
3.5.7 Decommissioning, storage and disposal.............................................................. 26
4 Technical data.......................................................................................... 27
4.1 Technical data, overview....................................................................................... 27
4.2 Technical data, KR 6 R700-2................................................................................ 28
4.2.1 Basic data, KR 6 R700-2...................................................................................... 28
4.2.2 Axis data, KR 6 R700-2........................................................................................ 29
4.2.3 Payloads, KR 6 R700-2........................................................................................ 32
4.2.4 Foundation loads, KR 6 R700-2........................................................................... 39
4.3 Technical data, KR 6 R900-2................................................................................ 40
4.3.1 Basic data, KR 6 R900-2...................................................................................... 40
4.3.2 Axis data, KR 6 R900-2........................................................................................ 42
4.3.3 Payloads, KR 6 R900-2........................................................................................ 46
4.3.4 Foundation loads, KR 6 R900-2........................................................................... 52
4.4 Technical data, KR 10 R900-2.............................................................................. 54
4.4.1 Basic data, KR 10 R900-2.................................................................................... 54
4.4.2 Axis data, KR 10 R900-2...................................................................................... 56
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KR AGILUS-2
4.4.3 Payloads, KR 10 R900-2...................................................................................... 59

4.4.4 Foundation loads, KR 10 R900-2......................................................................... 65
4.5 Technical data, KR 10 R1100-2............................................................................ 67
4.5.1 Basic data, KR 10 R1100-2.................................................................................. 67
4.5.2 Axis data, KR 10 R1100-2.................................................................................... 69
4.5.3 Payloads, KR 10 R1100-2.................................................................................... 72
4.5.4 Foundation loads, KR 10 R1100-2....................................................................... 78
4.6 Plates and labels................................................................................................... 80
4.7 REACH duty to communicate information acc. to Art. 33................................... 82
4.8 Stopping distances and times............................................................................... 83
4.8.1 General information............................................................................................... 83
4.8.2 Stopping distances and times, KR 6 R700-2....................................................... 83
4.8.2.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3................ 83
4.8.2.2 Stopping distances and stopping times for STOP 1, axis 1................................ 84
4.8.3 Stopping distances and times, KR 6 R900-2....................................................... 88
4.8.4 Stopping distances and times, KR 10 R900-2..................................................... 93
4.8.5 Stopping distances and times, KR 10 R1100-2................................................... 98
5 Planning.................................................................................................... 105
5.1 Information for planning........................................................................................ 105
5.2 Mounting base....................................................................................................... 105
5.3 Machine frame mounting....................................................................................... 108
5.4 Connecting cables and interfaces......................................................................... 110
5.4.1 Energy supply system CTR AIR........................................................................... 112
5.4.2 Energy supply system AIR CTR GIG................................................................... 114
6 Transportation.......................................................................................... 121
6.1 Transporting the manipulator................................................................................ 121
7 Appendix................................................................................................... 125
7.1 Applied standards and regulations....................................................................... 125
8 KUKA Service........................................................................................... 127

8.1 Requesting support............................................................................................... 127
8.2 KUKA Customer Support...................................................................................... 127
Index 129

KR AGILUS-2
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 engineering
• 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 Industrial robot documentation
The industrial robot documentation consists of the following parts:
• Documentation for the robot arm

• 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 of these sets 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.
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.

KR AGILUS-2
This warning draws attention to procedures which serve to prevent or rem-

Introduction
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
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.
AIR Air
Cable set: air line
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.
Extension Distance (l in %) between axis 1 and the intersection of axes 4 and

5. With parallelogram robots, the distance between axis 1 and the
intersection of axis 6 and the mounting flange.
CTR Control
Cable set: control cable
EDS Electronic Data Storage

(memory card)
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
GIG Gigabit
Cable set: Ethernet cable

KR AGILUS-2
Introduction
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.
KL KUKA linear unit
KR C KUKA Robot Control

Robot controller
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
Manipulator The robot arm and the associated electrical installations
MEMD Micro Electronic Mastering Device
Phi Angle of rotation (°) about the corresponding axis. This value can
be entered in the controller via the teach pendant, from which it
can be read.
POV Program override (%) = velocity of the robot motion. This value can
be entered in the controller via the teach pendant, from which it
can be read.
RDC Resolver Digital Converter

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).
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.

Introduction KR AGILUS-2
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.
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.
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

KR AGILUS-2
Product description
2 Product description
2.1 Overview of the robot system
A robot system (>>> Fig. 2-1) comprises all the assemblies of an industri-
al robot, including the manipulator (mechanical system and electrical in-
stallations), control cabinet, connecting cables, end effector (tool) and oth-
er equipment. The KR AGILUS-2 product family comprises the robot var-
iants:
• KR 6 R700-2
• KR 6 R900-2
• KR 10 R900-2
• KR 10 R1100-2
An industrial robot of this product family comprises the following compo-
nents:
• Manipulator
• Robot controller
• Connecting cables
• KUKA smartPAD teach pendant
• Software
• Options, accessories
Fig. 2-1: Example of an industrial robot
1 Manipulator
2 Teach pendant, KUKA smartPAD
3 Connecting cable/KUKA smartPAD
4 Robot controller
5 Connecting cable/data cable
6 Connecting cable/motor cable
7 Device connection cable

Product description KR AGILUS-2
2.2 Description of the manipulator
Overview
The manipulators (= robot arm and electrical installations) of the variants

are designed as 6-axis jointed-arm kinematic systems made of cast light
alloy. Each axis is fitted with a brake. All motor units and current-carrying
cables are protected against dirt and moisture beneath screwed-on cover
plates.
The manipulators consist of the following main assemblies:
• In-line wrist
• Arm
• Link arm
• Rotating column
• Base frame
• Electrical installations
Fig. 2-2: Principal components
1 In-line wrist 4 Rotating column

2 Arm 5 Electrical installations
3 Link arm 6 Base frame
In-line wrist – A4, A5, A6
The robot is fitted with a 3-axis in-line wrist. The in-line wrist consists of
axes 4, 5 and 6.
Interface A4 for the energy supply system is located on the side of the in-
line wrist.
Further information can be found in the chapter (>>> 5.4 "Connecting ca-
bles and interfaces" Page 110).
Arm – A3
The arm is the link between the in-line wrist and the link arm. The arm is
driven by the motor of axis 3.

KR AGILUS-2
Product description
Link arm – A2
The link arm is the assembly located between the arm and the rotating
column. It houses the motor and gear unit of axis 3. The supply lines of
the energy supply system and the cable set for axes 2 to 6 are routed
through the link arm.
Rotating column – A1
The rotating column houses the motors of axes 1 and 2. The rotational
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 link arm is also mounted in the rotating column.
Base frame
The base frame is the base of the robot. Interface A1 is located at the
rear of the base frame. It constitutes the interface for the connecting ca-
bles between the robot, the controller and the energy supply system.
Electrical installations
The electrical installations include all the motor and data cables for the
motors of axes 1 to 6, as well as the connections for the internal energy
supply system and external axes A7 and A8. All connections are plugga-
ble. The electrical installations also include the RDC, which is integrated
into the robot. The connectors for the motor and data cables are mounted
on the robot base frame. The connecting cables from the robot controller
are connected here by means of connectors. The electrical installations al-
so include a protective circuit.
Options
The robot can be fitted and operated with various options, e.g. axis limita-
tion A1 or brake release device. The option is described in separate doc-
umentation.
The following options are also available:
• Connector bypack CTR AIR
• Connector bypack AIR CTR GIG
• Optional connecting cables
2.3 Intended use and misuse
Intended use
The industrial robot is intended for handling tools and fixtures or for pro-
cessing and transferring components or products. Use is only permitted
under the specified environmental conditions.
Operation of the industrial robot in accordance with its intended use also
requires compliance with the operating and assembly instructions for the
individual components, with particular reference to the maintenance speci-
fications.
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

Product description KR AGILUS-2
• Operation outside the specified operating parameters

• Operation without the required safety equipment
• Transportation of persons and animals
• Outdoor operation.
• Use in a potentially explosive area
• Use in radioactive environments
• Operation in underground mining
NOTICE
Deviations from the operating conditions specified in the technical data
or the use of special functions or applications can lead to premature
wear. KUKA Deutschland GmbH must be consulted.
The robot system is an integral part of a complete system and may only
be operated in a CE-compliant system.

KR AGILUS-2
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.

Safety KR AGILUS-2
3.1.2 EC declaration of conformity and declaration of incorporation
The industrial robot constitutes partly completed machinery as defined by

the EC Machinery Directive. The industrial robot may only be put into 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.

KR AGILUS-2
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.
Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.


Safety KR AGILUS-2
Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking.

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.
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).

KR AGILUS-2
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

Safety KR AGILUS-2
• 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:

KR AGILUS-2
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

KR AGILUS-2
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.

KR AGILUS-2
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.

Safety KR AGILUS-2
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.

KR AGILUS-2
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.

Safety KR AGILUS-2
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)

KR AGILUS-2
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.

Safety KR AGILUS-2
• 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.

KR AGILUS-2
Technical data
4 Technical data
4.1 Technical data, overview
The technical data for the individual robot types can be found in the fol-
lowing sections:
Robot Technical data
KR 6 R700-2 • Technical data
(>>> 4.2 "Technical data, KR 6 R700-2" Page 28)
• Supplementary loads
• Plates and labels
(>>> 4.6 "Plates and labels" Page 80)
• Stopping distances and times
(>>> 4.8.2 "Stopping distances and times, KR 6 R700-2"
Page 83)
Page 88)
Page 93)
Page 98)

Technical data KR AGILUS-2
4.2 Technical data, KR 6 R700-2
4.2.1 Basic data, KR 6 R700-2
Basic data
KR 6 R700-2
Number of axes 6
Number of controlled axes 6
Volume of working envelope 1.47 m³
Pose repeatability (ISO 9283) ± 0.02 mm
Weight approx. 53 kg
Rated payload 3 kg
Maximum payload 6.8 kg
Maximum reach 726 mm
Protection rating (IEC 60529) IP65 / IP67
Protection rating, in-line wrist (IEC IP65 / IP67
60529)
Sound level < 57 dB (A)
Mounting position Floor;
Ceiling;
Wall;
Desired angle
Footprint 208 mm x 208 mm
Hole pattern: mounting surface for C246
kinematic system
Permissible angle of inclination -
Default color Base frame: gray aluminum (RAL
9007);
Moving parts: traffic white (RAL
9016)
Controller KR C4 smallsize-2;
KR C4 compact
Transformation name KR C4: KR6R700_2 C4SR
Protection classification IP67 can only be assured with a compressed air
connection (venting connection PURGE) of 0.3 bar.
Overpressure in the robot 0.03 MPa (0.3 bar)
Compressed air Oil-free, dry, filtered
in accordance with: ISO 8573.1-1,
1.2 to 16.2
Air consumption 0.1 m3/h
Air line connection Plug-in connection for hose, stand-
ard outside diameter 4 mm
Number of cycles 138 Cycles per minute

Time per cycle 0.43 s
Palletizing distance 25 mm / 305 mm / 25 mm, 1 kg

KR AGILUS-2
Technical data
Fig. 4-1: Palletizing cycle
Ambient conditions
Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 0 °C to 45 °C (273 K to 318 K)
During storage/transportation -40 °C to 60 °C (233 K to 333 K)
For operation at low temperatures, it may be necessary to warm up the

robot.
Connecting cables
Connector designation
Interface with
Cable designation robot controller -
robot
robot
Motor cable X20 - X30 Han Yellock 30
Data cable X21 - X31 Han Q12
Ground conductor, equi- M4 ring cable
potential bonding lug
(optional)
Cable lengths 1 m, 4 m, 7 m, 15 m, 25 m
Max. cable length 25 m
Number of extensions 1
For detailed specifications of the connecting cables, see “Description of
the connecting cables”.
Certificates
ESD requirements IEC61340-5-1; ANSI/ESD S20.20
4.2.2 Axis data, KR 6 R700-2
Axis data
Motion range
A1 ±170 °
A2 -190 ° / 45 °
A3 -120 ° / 156 °
A4 ±185 °
A5 ±120 °
A6 ±350 °
Speed with rated payload

A1 360 °/s
A2 300 °/s
A3 360 °/s
A4 450 °/s
A5 450 °/s
A6 540 °/s
In the case of manipulators with a payload of 6 kg and a reach of

R700, not every angle for axis A4 can be reached in the end position.
The direction of motion and the arrangement of the individual axes may
be noted from the diagram (>>> Fig. 4-2).
Fig. 4-2: Direction of rotation of robot axes
Mastering positions
Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 90 °
A5 0 °
A6 0 °
Working envelope
The following diagrams show the shape and size of the working envelope
for these variants of this product family.
The reference point for the working envelope is the intersection of axes 4
and 5.

KR AGILUS-2
Technical data
Fig. 4-3: KR 6 R700-2, working envelope, side view
Fig. 4-4: KR 6 R700-2, working envelope, top view
Inclined installation
The robot can be installed in any position from 0° (floor) to 180° (ceiling).
The following figure shows the possible limitation of the motion range of
axis 1, as a function of the angle of inclination of the robot.
The inclination angles for the robot must be entered correctly into the con-
troller if the robot is not operated in the floor-mounted position. Configura-
tion of the angles is possible via WorkVisual.
The inclination angles for an unchanged main working direction of the ro-
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°

CAUTION
The inclined installation angles must be individually checked and en-
tered. An incorrectly entered inclined installation angle can lead to un-
foreseen motion and/or to an overload and, potentially, damage to the
robot.
Fig. 4-5: Motion range of A1 with inclined installation, KR 6 R700-2
4.2.3 Payloads, KR 6 R700-2
Payloads
Rated payload 3 kg
Rated mass moment of inertia for 0.045 kgm²
flange Ix
flange Iy
flange Iz

KR AGILUS-2
Technical data
Rated supplementary load, base 0 kg
frame
Maximum supplementary load, 0 kg
base frame
Rated supplementary load, rotating 0 kg
column
Maximum supplementary load, ro- 1 kg
tating column
Rated supplementary load, link 0 kg
arm
Maximum supplementary load, link 1 kg
arm
Rated supplementary load, arm 0 kg
Maximum supplementary load, arm 2 kg
Nominal distance to load center of gravity
Lxy 60 mm
Lz 80 mm
The sum of all loads mounted on the robot must not exceed the maxi-
mum payload.
Load center of gravity and mass moment of inertia
Fig. 4-6: Load center of gravity and mass moment of inertia
Parameter
Parameter/unit Description
Mass kg Payload mass
Lx, Ly, Lz mm Position of the center of mass in the reference
system

A, B, C Degrees Orientation of the principal inertia axes
• A: Rotation about the Z axis of the refer-

ence system
The result is a coordinate system named
CS'.
• B: Rotation about the Y axis of CS'
Result: CS''
• C: Rotation about the X axis of CS''
Note: A, B and C are not shown in the dia-
gram.
Mass moments of inertia:

Ix kgm2 Inertia about the X axis of the main axis sys-
tem
Iy kgm2 Inertia about the Y axis of the main axis sys-
tem
Iz kgm2 Inertia about the Z axis of the main axis sys-
tem
Lx, Ly, Lz and A, B, C unambiguously define the main axis system:
• The origin of the main axis system is the center of mass.
• A characteristic feature of the main axis system is that, among other
things, the maximum possible inertia occurs about one of the 3 coordi-
nate axes.
More information is contained in the KUKA.Load documentation.
Payload diagram
NOTICE
This loading curve corresponds to the maximum load capacity. Both val-
ues (payload and mass moment of inertia) must be checked in all ca-
ses. Exceeding this capacity will reduce the service life of the robot and
overload the motors and the gears; in any such case KUKA Deutsch-
land GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot appli-
cation. For commissioning the robot, additional input data are required
in accordance with the operating and programming instructions of the
KUKA System Software.
The mass inertia must be verified using KUKA.Load or KUKA Compose.
It is imperative for the load data to be entered in the robot controller!

KR AGILUS-2
Technical data
Fig. 4-7: KR 6 R700-2, payload diagram
The KR 6 R700-2 is designed for a rated payload of 3 kg in order to opti-

mize the dynamic performance of the robot. With reduced load center dis-
tances and a supplementary load optimized for the load case (if necessa-
ry), even higher loads up to the maximum payload of 6.8 kg may be
used. The specific load case must be verified using KUKA.Load. For fur-
ther consultation, please contact KUKA Support.
Mounting flange
In-line wrist type ZH Arm KR6

Mounting flange see drawing
Mounting flange (hole circle) 31.5 mm

Screw grade 12.9
Screw size M5
Number of fastening threads 7
Clamping length min. 1.5 x nominal diameter
Depth of engagement min. 5.5 mm, max. 7 mm
Locating element 5 H7
Standard See diagram (>>> Fig. 4-8)

The mounting flange is depicted (>>> Fig. 4-8) with axes 4 and 6 in the
zero position. The symbol Xm indicates the position of the locating ele-
ment (bushing) in the zero position.

Fig. 4-8: Mounting flange
Flange loads
Due to the motion of the payload (e.g. tool) mounted on the robot, forces
and torques act on the mounting flange. These forces and torques depend
on the motion profile as well as the mass, load center of gravity and mass
moment of inertia of the payload.
The specified values refer to nominal payloads at the nominal distance
and do not include safety factors. It is imperative for the load data to be
entered in the robot controller. The robot controller takes the payload into
consideration during path planning. A reduced payload does not necessa-
rily result in lower forces and torques.
The values are guide values determined by means of trial and simulation
and refer to the most heavily loaded machine in the robot family. The ac-
tual forces and torques may differ due to internal and external influences
on the mounting flange or a different point of application. It is therefore
advisable to determine the exact forces and torques where necessary on
site under the real conditions of the actual robot application.
The operating values may occur permanently in the normal motion profile.
It is advisable to rate the tool for its fatigue strength.
The EMERGENCY STOP values may arise in the event of an Emergency
Stop situation of the robot. As these should only occur very rarely during
the service life of the robot, a static strength verification is usually suffi-
cient.

KR AGILUS-2
Technical data
Fig. 4-9: Flange loads
Flange loads during operation

F(a) 209 N
F(r) 235 N
M(k) 31 Nm
M(g) 17 Nm
Flange loads in the case of EMERGENCY STOP
F(a) 324 N
F(r) 297 N
M(k) 36 Nm
M(g) 24 Nm
Axial force F(a), radial force F(r), tilting torque M(k), torque about mount-
ing flange M(g)
Supplementary load
The robot can carry supplementary loads on the arm, link arm and rotat-
ing column. The fastening holes on the arm, link arm and rotating column
are used, for example, for fastening the covers or external energy supply
systems. The fastening holes on the in-line wrist are exclusively for fasten-
ing holders for energy supply systems (e.g. holders for compressed air
hose).
When mounting the supplementary loads, be careful to observe the maxi-
mum permissible total load. The dimensions and positions of the installa-
tion options can be seen in the following diagram.
mum total load.

Fig. 4-10: Installation options on arm and in-line wrist
1 Fastening holes, in-line wrist

2 Support for supplementary load, arm
Fig. 4-11: Installation options on link arm and rotating column
1 Support for supplementary load, link arm

2 Fastening holes, link arm
3 Support for supplementary load, rotating column
For the fastening holes on the link arm, the following must be observed:
• Screw without supplementary load: 2x M4x8-8.8-A2K
• Screw with supplementary load: 8 mm + part thickness of supplemen-
tary load + max. 1 mm

KR AGILUS-2
Technical data
4.2.4 Foundation loads, KR 6 R700-2
Foundation loads
The specified forces and moments already include the payload and the in-
ertia force (weight) of the robot.
Foundation loads for floor mounting position
F(v normal) 801 N
F(v max) 1105 N
F(h normal) 451 N
F(h max) 684 N
M(k normal) 420 Nm
M(k max) 595 Nm
M(r normal) 162 Nm
M(r max) 301 Nm
Foundation loads for ceiling mounting position
F(v normal) 909 N
F(v max) 949 N
F(h normal) 472 N
F(h max) 677 N
M(k normal) 440 Nm
M(k max) 649 Nm
M(r normal) 180 Nm
M(r max) 307 Nm
Foundation loads for wall mounting position
F(v normal) 900 N
F(v max) 1016 N
F(h normal) 320 N
F(h max) 593 N
M(k normal) 459 Nm
M(k max) 712 Nm
M(r normal) 172 Nm
M(r max) 285 Nm
Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about
axis 1 M(r)

Fig. 4-12: Foundation loads
WARNING
Normal loads and maximum loads for the foundations are specified in
the table.
The maximum loads must be referred to when dimensioning the 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.
The supplementary loads (A1 and A2) are not taken into consideration
in the calculation of the mounting base load. These supplementary
loads must be taken into consideration for Fv.
Basic data
KR 6 R900-2
Number of axes 6
Rated payload 3 kg

KR AGILUS-2
Technical data
KR 6 R900-2
60529)
Ceiling;
Wall;
Desired angle
kinematic system
9007);
9016)
KR C4 compact
1.2 to 16.2

Time per cycle -
Ambient conditions

Ambient temperature


robot.
Connecting cables
Interface with
robot
robot
(optional)
Certificates
4.3.2 Axis data, KR 6 R900-2
Axis data
Motion range
A1 ±170 °
A2 -190 ° / 45 °
A3 -120 ° / 156 °
A4 ±185 °
A5 ±120 °
A6 ±350 °
A1 360 °/s
A2 300 °/s
A3 360 °/s
A4 450 °/s
A5 450 °/s
A6 540 °/s

KR AGILUS-2
Technical data
Mastering positions
Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 90 °
A5 0 °
A6 0 °
Working envelope
and 5.


KR AGILUS-2
Technical data
Fig. 4-16: KR 6 R900-2, working envelope
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°

CAUTION
robot.
4.3.3 Payloads, KR 6 R900-2
Payloads
Rated payload 3 kg
flange Ix
flange Iy
flange Iz

KR AGILUS-2
Technical data
frame
base frame
column
tating column
arm
arm
Lxy 60 mm
Lz 80 mm
mum payload.
Parameter
system


ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE

KR AGILUS-2
Technical data
The KR 6 R900-2 is designed for a rated payload of 3 kg in order to opti-

mize the dynamic performance of the robot. With reduced load center dis-
tances and a supplementary load optimized for the load case (if necessa-
ry), even higher loads up to the maximum payload of 6.7 kg may be
Mounting flange


Screw grade 12.9
Screw size M5


Flange loads
cient.

KR AGILUS-2
Technical data

F(a) 215 N
F(r) 264 N
M(k) 27 Nm
M(g) 16 Nm
F(a) 323 N
F(r) 309 N
M(k) 35 Nm
M(g) 23 Nm
ing flange M(g)
Supplementary load
hose).
mum total load.

Foundation loads

KR AGILUS-2
Technical data
F(v normal) 873 N
F(v max) 1127 N
F(h normal) 563 N
F(h max) 756 N
M(k normal) 605 Nm
M(k max) 763 Nm
M(r normal) 200 Nm
M(r max) 334 Nm
F(v normal) 926 N
F(v max) 1055 N
F(h normal) 620 N
F(h max) 736 N
M(k normal) 624 Nm
M(k max) 763 Nm
M(r normal) 311 Nm
M(r max) 363 Nm
F(v normal) 1004 N
F(v max) 1115 N
F(h normal) 343 N
F(h max) 649 N
M(k normal) 619 Nm
M(k max) 864 Nm
M(r normal) 205 Nm
M(r max) 325 Nm
axis 1 M(r)

WARNING
the table.
Basic data
KR 10 R900-2
Number of axes 6
Rated payload 5 kg

KR AGILUS-2
Technical data
KR 10 R900-2
60529)
Ceiling;
Wall;
Desired angle
kinematic system
9007);
9016)
KR C4 compact
1.2 to 16.2

Time per cycle -
Ambient conditions

Ambient temperature


robot.
Connecting cables
Interface with
robot
robot
(optional)
Certificates
4.4.2 Axis data, KR 10 R900-2
Axis data
Motion range
A1 ±170 °
A2 -190 ° / 45 °
A3 -120 ° / 156 °
A4 ±185 °
A5 ±120 °
A6 ±350 °
A1 300 °/s
A2 225 °/s
A3 330 °/s
A4 360 °/s
A5 360 °/s
A6 433 °/s

KR AGILUS-2
Technical data
Mastering positions
Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 90 °
A5 0 °
A6 0 °
Working envelope
and 5.

bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°

KR AGILUS-2
Technical data
CAUTION
robot.
4.4.3 Payloads, KR 10 R900-2
Payloads
Rated payload 5 kg
flange Ix
flange Iy
flange Iz


frame
base frame
column
tating column
arm
arm
Lxy 100 mm
Lz 80 mm
mum payload.
Parameter
system

KR AGILUS-2
Technical data

ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE

The KR 10 R900-2 is designed for a rated payload of 5 kg in order to op-

timize the dynamic performance of the robot. With reduced load center
distances and a supplementary load optimized for the load case (if neces-
sary), even higher loads up to the maximum payload of 11.3 kg may be
Mounting flange


Screw grade 12.9
Screw size M5


KR AGILUS-2
Technical data
Flange loads
cient.


F(a) 275 N
F(r) 309 N
M(k) 35 Nm
M(g) 27 Nm
F(a) 460 N
F(r) 423 N
M(k) 60 Nm
M(g) 43 Nm
ing flange M(g)
Supplementary load
hose).
mum total load.

KR AGILUS-2
Technical data
Foundation loads


F(v normal) 866 N
F(v max) 1223 N
F(h normal) 499 N
F(h max) 693 N
M(k normal) 465 Nm
M(k max) 821 Nm
M(r normal) 226 Nm
M(r max) 403 Nm
F(v normal) 919 N
F(v max) 1052 N
F(h normal) 491 N
F(h max) 757 N
M(k normal) 475 Nm
M(k max) 892 Nm
M(r normal) 302 Nm
M(r max) 416 Nm
F(v normal) 1015 N
F(v max) 1121 N
F(h normal) 343 N
F(h max) 715 N
M(k normal) 619 Nm
M(k max) 879 Nm
M(r normal) 244 Nm
M(r max) 385 Nm
axis 1 M(r)

KR AGILUS-2
Technical data
WARNING
the table.
4.5.1 Basic data, KR 10 R1100-2
Basic data
KR 10 R1100-2
Number of axes 6
Rated payload 5 kg

KR 10 R1100-2
60529)
Ceiling;
Wall;
Desired angle
kinematic system
9007);
9016)
KR C4 compact
1.2 to 16.2

Time per cycle -
Ambient conditions

Ambient temperature

KR AGILUS-2
Technical data
robot.
Connecting cables
Interface with
robot
robot
(optional)
Certificates
4.5.2 Axis data, KR 10 R1100-2
Axis data
Motion range
A1 ±170 °
A2 -190 ° / 45 °
A3 -120 ° / 156 °
A4 ±185 °
A5 ±120 °
A6 ±350 °
A1 300 °/s
A2 225 °/s
A3 330 °/s
A4 360 °/s
A5 360 °/s
A6 433 °/s

Mastering positions
Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 90 °
A5 0 °
A6 0 °
Working envelope
and 5.

KR AGILUS-2
Technical data
bot:
Floor: A:0°, B:0°, C:0°
Wall: A:0°, B:90°, C:0°
Ceiling: A:0°, B:0°, C:180°

CAUTION
robot.
Fig. 4-41: Motion range of A1 with inclined installation
4.5.3 Payloads, KR 10 R1100-2
Payloads
Rated payload 5 kg
flange Ix
flange Iy
flange Iz

KR AGILUS-2
Technical data
frame
base frame
column
tating column
arm
arm
Lxy 100 mm
Lz 80 mm
mum payload.
Parameter
system


ence system
CS'.
Result: CS''
gram.

tem
tem
tem
nate axes.
Payload diagram
NOTICE

KR AGILUS-2
Technical data
The KR 10 R1100-2 is designed for a rated payload of 5 kg in order to

optimize the dynamic performance of the robot. With reduced load center
distances and a supplementary load optimized for the load case (if neces-
sary), even higher loads up to the maximum payload of 11.1 kg may be
Mounting flange


Screw grade 12.9
Screw size M5


Flange loads
cient.

KR AGILUS-2
Technical data

F(a) 289 N
F(r) 265 N
M(k) 34 Nm
M(g) 27 Nm
F(a) 390 N
F(r) 407 N
M(k) 54 Nm
M(g) 42 Nm
ing flange M(g)
Supplementary load
hose).
mum total load.

Foundation loads

KR AGILUS-2
Technical data
F(v normal) 916 N
F(v max) 1200 N
F(h normal) 558 N
F(h max) 762 N
M(k normal) 542 Nm
M(k max) 894 Nm
M(r normal) 249 Nm
M(r max) 430 Nm
F(v normal) 957 N
F(v max) 1156 N
F(h normal) 575 N
F(h max) 805 N
M(k normal) 574 Nm
M(k max) 913 Nm
M(r normal) 282 Nm
M(r max) 455 Nm
F(v normal) 1018 N
F(v max) 1172 N
F(h normal) 425 N
F(h max) 711 N
M(k normal) 688 Nm
M(k max) 1038 Nm
M(r normal) 280 Nm
M(r max) 420 Nm
axis 1 M(r)

WARNING
the table.
4.6 Plates and labels
Plates and labels
The following plates and labels are attached to the robot. They must not
be removed or rendered illegible. Illegible plates and labels must be re-
placed.

KR AGILUS-2
Technical data
Fig. 4-49: Plates and labels
Item Description
1
Secure the axes

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
Transport position
Before loosening the bolts of the mounting base, the robot must
be in the transport position as indicated in the table. Risk of
toppling!

Item Description
3
Danger zone
Entering the danger zone of the robot is prohibited if the robot
is in operation or ready for operation. Risk of injury!
4
Work on the robot

Before start-up, transportation or maintenance, read and follow
the assembly and operating instructions.
5
Identification plate example

Content according to Machinery Directive.
The QR code contains a link to product information in KUKA
Xpert.
4.7 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.

KR AGILUS-2
Technical data
4.8 Stopping distances and times
4.8.1 General information
Information concerning the data:
• The stopping distance is the angle traveled by the robot from the mo-
ment the stop signal is triggered until the robot comes to a complete
standstill.
• The stopping time is the time that elapses from the moment the stop
signal is triggered until the robot comes to a complete standstill.
• The data are given for the main axes A1, A2 and A3. The main axes
are the axes with the greatest deflection.
• Superposed axis motions can result in longer stopping distances.
• Stopping distances and stopping times in accordance with DIN EN
ISO 10218-1, Annex B.
• Stop categories:
‒ Stop category 0 » STOP 0
‒ Stop category 1 » STOP 1
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 which con-
form to the requirements of DIN EN ISO 10218-1. The actual stopping
distances and stopping times may differ due to internal and external
influences on the braking torque. It is therefore advisable to determine
the exact stopping distances and stopping times where necessary un-
der the real conditions of the actual robot 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.
4.8.2 Stopping distances and times, KR 6 R700-2
4.8.2.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3
The table shows the stopping distances and stopping times after a STOP
0 (category 0 stop) is triggered. The values refer to the following configu-
ration:
• Extension l = 100%
• Program override POV = 100%
• Mass m = maximum load (rated load + supplementary load on arm)
Stopping distance (°) Stopping time (s)

Axis 1 33.06 0.39
Axis 2 38.65 0.22
Axis 3 36.40 0.16

KR AGILUS-2
4.8.2.2 Stopping distances and stopping times for STOP 1, axis 1

Technical data
Fig. 4-50: Stopping distances for STOP 1, axis 1

KR AGILUS-2
Technical data
Fig. 4-51: Stopping times for STOP 1, axis 1

KR AGILUS-2

Technical data

KR AGILUS-2
Technical data

KR AGILUS-2

Technical data
ration:

Axis 1 39.92 0.22
Axis 2 35.49 0.24

KR AGILUS-2
Technical data
Axis 3 34.78 0.17


KR AGILUS-2
Technical data


KR AGILUS-2
Technical data
ration:

Axis 1 34.13 0.22
Axis 2 21.45 0.18


Axis 3 32.87 0.19

KR AGILUS-2
Technical data

KR AGILUS-2

Technical data

KR AGILUS-2
Technical data

KR AGILUS-2

Technical data
ration:

Axis 1 28.77 0.22
Axis 2 23.55 0.22

KR AGILUS-2
Technical data
Axis 3 28.47 0.17


KR AGILUS-2
Technical data


KR AGILUS-2
Technical data


KR AGILUS-2
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
• Static axis positions, e.g. continuous vertical position of a wrist axis
• External forces (process forces) acting on the robot
If one or more of these conditions arise during operation of the kinematic
system, KUKA Deutschland GmbH must be consulted.
If the robot reaches its corresponding operation limit or if it is operated
near the limit for a period of time, the built-in monitoring functions come
into effect and the robot is automatically switched off.
This protective function can limit the availability of the robot system.
5.2 Mounting base
Description
The mounting base with centering is used when the robot is fastened to
the floor, i.e. directly on a concrete foundation.
The mounting base with centering consists of:
• Bedplate
• 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 bedplate and
the concrete foundation.
The minimum dimensions must be observed.

Planning KR AGILUS-2
Fig. 5-1: Mounting base
1 Robot base frame 4 Hexagon bolt

2 Locating pin, cylindrical 5 Bedplate
3 Resin-bonded anchor 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.

KR AGILUS-2
Planning
Fig. 5-2: Mounting base, dimensioned drawing
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration (>>> Fig. 5-3).
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.

Fig. 5-3: Cross-section of foundations
1 Hexagon bolt 4 Resin-bonded anchor

2 Bedplate 5 Concrete foundation
3 Locating pin
5.3 Machine frame mounting
Description
The machine frame mounting assembly is used when the robot is fas-
tened on a steel structure, a booster frame (pedestal) or a KUKA linear
unit. This assembly is also used if the robot is installed on the wall or ceil-
ing. It must be ensured that the substructure is able to withstand safely
the forces occurring during operation (foundation loads). The following dia-
gram 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

KR AGILUS-2
Planning
Fig. 5-4: Machine frame mounting
1 Hexagon bolt
2 Locating pin, cylindrical
3 Locating pin, flat-sided
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. 5-5) provides all the necessary informa-
tion on machine frame mounting, together with the required foundation da-
ta.

Fig. 5-5: Machine frame mounting, dimensioned drawing
1 Hexagon bolt (4x) 4 Locating pin, flat-sided

2 Locating pin, cylindrical 5 Steel structure
3 Mounting surface
5.4 Connecting cables and interfaces
Connecting cables
The connecting cables comprise all the cables for transferring energy and
signals between the robot and the robot controller. They are connected on
the robot side with connectors at interface A1. Connection to the controller
is always the same, irrespective of the controller variant.
Cable lengths of 1 m, 4 m, 7 m, 15 m and 25 m are available as stand-
ard. The maximum length of the connecting cables must not exceed
25 m. The connecting cables may be extended a maximum of 1 time, i.e.
a maximum of 2 connecting cables may be combined with each other.

KR AGILUS-2
Thus if the robot is operated on a linear unit which has its own energy
Planning
supply chain, this cable must also be taken into account.
For the connecting cables, an additional ground conductor is always re-
quired to provide a low-resistance connection between the robot and the
control cabinet in accordance with DIN EN 60204. The ground conductor
is connected via ring cable lugs. The threaded bolts for connecting the
two ground conductors are located on the base frame of the robot.
The following points must be observed when planning and routing the
connecting cables:
• The bending radius for fixed routing must not be less than 50 mm for
motor cables and 30 mm for control 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 318 K (+45 °C).
• Route the motor cables and the data cables separately in metal ducts;
if necessary, additional measures must be taken to ensure electromag-
netic compatibility (EMC).
CAUTION
Risk of injury due to tripping hazards
Improper installation of cables can cause tripping hazards. Injuries or
damage to property may result.
• The connecting cables must be installed in such a way (e.g. cable
ducts) as to prevent tripping hazards.
• Potential tripping hazards must be marked accordingly.
Interface A1
Interface A1 is located at the rear of the base frame. The connections for
the motor and data cables are shown in the following illustration.
Fig. 5-6: Interface A1
1 Motor cable connection X30

2 Data cable connection X31

Interface for energy supply system
Depending on the selected variant, the robot contains different energy

supply system options. The connections of the energy supply system are
located at interface plate A1 and on the side of the robot wrist (A4). De-
tailed information about the energy supply system option, e.g. connectors
and connector pin allocation, can be found under (>>> 5.4.1 "Energy sup-
ply system CTR AIR" Page 112) and (>>> 5.4.2 "Energy supply system
AIR CTR GIG" Page 114).
5.4.1 Energy supply system CTR AIR
Customer interface A1
Customer interface A1 is located at the rear of the base frame.
Fig. 5-7: Customer interface A1, CTR AIR
1 Connection MEMD X32

2 PURGE venting connection (optionally for IP67)
Max. pressure: 0.3 bar
Air, oil-free, dry, filtered
according to: ISO 8573.1-1, 1.2 to 16.2
3 Connection for air line AIR 1
Outside diameter: 4 mm
4 I/O cable connection X76
Customer interface A4
Customer interface A4 is located on the side of the in-line wrist.

KR AGILUS-2
Planning
Fig. 5-8: Customer interfaces A4, example
1 Connection X96 4 Air line AIR3

2 Air line AIR2 5 Air line AIR1
3 Air line AIR4
The optional connector bypack is required for use of connection X76/X96.
Energy supply system

X76-X96
Designation Limit values

Rated current 2 A
Rated voltage 24 V
Connector type M12
Number of poles 8
Coding A standard
The entire energy supply system must be safeguarded against overload
and short circuit by the customer upstream of connector X76.
The following connectors are required for connections X76 and X96:
• X76: M12, female, A-coded, 8-pole
• X96: M12, male, A-coded, 8-pole

Fig. 5-9: Wiring diagram, energy supply system, X76-X96
Air connections
AIR 1 to AIR 4
Customer-specific air connections AIR 1 to AIR 4 with the following val-

ues:
Max. pressure 7 bar
Vacuum Atmospheric pressure minus 0.95 bar
5.4.2 Energy supply system AIR CTR GIG
Customer interfaces A1
Customer interfaces A1 are located at the rear of the base frame.

KR AGILUS-2
Planning
Fig. 5-10: Customer interface A1, AIR CTR GIG
1 MEMD connection X32

2 PURGE venting connection (optionally for IP67)
Max. pressure: 0.3 bar
Air, oil-free, dry, filtered
according to: ISO 8573.1-1, 1.2 to 16.2
3 Air line connection AIR1 (valve unit)
4 Fuse for I/O and power supply (F41-F3A)
5 CAT5e data cable connection X74
Gigabit Ethernet (1000 Base-T)
6 Air line connection AIR2
7 Connection for external axis A8 (XP8.1)
8 Connection for external axis A7 (XP7.1)
Fuse F41-F3A
The fuse protects the digital inputs and outputs, the power supply and the
valve activation against overloading.
Fuse Miniature fuse
Type Fine-wire fuse, 5x20 mm
Tripping characteristic Quick-acting
Switching capacity 3 A
Interface A4
Customer interface A4 is located on the side of the in-line wrist.

Fig. 5-11: Customer interfaces A4, example
1 Connection X41 4 Valve venting R

2 Air connections, valve unit 5 Air line AIR2
3 Connection X94
The inputs and outputs are not preconfigured and must be configured in
WorkVisual.
Further information about mapping inputs and outputs can be found in
the WorkVisual documentation.
Signal table for interface A4:

Name WorkVisual
Input/output Notice
EM8905-1001
Channel 1 DI1
Channel 2 DI2
Digital input, customer interface X41
Channel 3 DI3
Input
Channel 4 DI4
Channel 5 DI5 Not assigned
Channel 6 DI6 Not assigned
Channel 7 DO1 Valve 2/12 (2B)
Channel 8 DO2 Valve 2/14 (2A)
Channel 9 DO3 Not assigned
Channel 10 DO4 Valve 1/12 (1B)
Output
Channel 11 DO5 Valve 1/14 (1A)
Channel 12 DO6 Not assigned
Channel 13 DO7 Digital output, customer interface
Channel 14 DO8 X41
Valve activation

Valve type 5/3-way solenoid valve
Operating pressure min. 3 bar, max. 7 bar
Switching frequency 10 Hz
Threaded union M5

KR AGILUS-2
Planning
Medium Air, oil-free, dry, filtered
according to: ISO 8573.1-1, 1.2 to
16.2
Degree of filtration: max. 5 µm
Operating temperature: +5 °C to
+45 °C (278 K to 318 K)
Free from condensation
Digital outputs (for valve activation) 4
Not short-circuit proof
Rated voltage 24 V DC (-15%/+20%)
Output current max. 25 mA
Fig. 5-12: Valve diagram
Connection X41
Designation Values
Digital outputs (for customer interface 2
X41)
short-circuit proof
Rated voltage 24 V DC (-15%/+20%)
Output current max. 0.5 A
Short-circuit current max. 2 A

Designation Values
Load type Ohmic, inductive
Lamp load
Digital inputs (for customer interface X41) 4
Signal voltage “0” -3 V … +5 V
EN 61131-2, type 3
Signal voltage “1” 15 V … 30 V
EN 61131-2, type 3
Input current Typically 3 mA
EN 61131-2, type 3
Input filter Typically 0.3 ms
Power supply 24 V / 3 A
If 3 A is selected, no digital
outputs/valves can be
switched.
Connector type M12
Number of poles 8
Coding A standard
An M12, male, A-coded, 8-pole connector is required for connection X41.
Fig. 5-13: Wiring diagram, connection X41
Connection X94

Connector type M12
Number of poles 8
Coding X standard
An M12, male, X-coded, 8-pole connector is required for connections X74
and X94.

KR AGILUS-2
Planning
Fig. 5-14: Wiring diagram, connection X94
Air connection AIR 2
Customer-specific air connection AIR 2 with the following values:

Max. pressure 7 bar
Vacuum Atmospheric pressure minus 0.95 bar


KR AGILUS-2
Transportation
6 Transportation
6.1 Transporting the manipulator
Description
Move the robot into its transport position each time it is transported. It
must be ensured that the robot is stable while it is being transported. The
robot must remain in its transport position until it has been fastened to the
foundation. Before the robot 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 glue on contact surfa-
ces.
Transport position
The robot must be in the transport position before it can be transported

(>>> Fig. 6-1). The robot is in the transport position when the axes are in
the following positions:
Axis A1 A2 A3 A4 A5 A6
Angle 0° -105° +156° 0º +39º 0º
Fig. 6-1: Transport position
Transport dimensions
The transport dimensions for the robot can be noted from the following fig-
ures. The position of the center of gravity and the weight vary according
to the specific configuration. The specified dimensions refer to the robot
without equipment.

Transportation KR AGILUS-2
Fig. 6-2: Transport dimensions
1 Robot 3 Fork slots

2 Center of gravity
Transport dimensions and centers of gravity
Robot A B C D E F
KR 6 R700-2 804 231 466 11 367 6
KR 6 R900-2
919 234 470 11 407 1
KR 10 R900-2
KR 10 R1100-2 1021 267 502 10 439 4
Transportation using lifting tackle (optional)
WARNING
Use of unsuitable handling equipment may result in damage to the robot
or injury to persons. Only use authorized handling equipment with a suf-
ficient load-bearing capacity. Only transport the robot in the manner
specified here.
The robot is transported using lifting tackle (optional) (>>> Fig. 6-3). For
this, it must be in the transport position. The loops of the lifting tackle (op-
tional) are passed around the link arm on the rotating column. All ropes
must be long enough and must be routed in such a way that the robot is
not damaged. Installed tools and items of equipment can cause undesira-
ble shifts in the center of gravity.

KR AGILUS-2
Transportation
WARNING
The robot may tip during transportation. Risk of personal injury and
damage to property.
If the robot is being transported using lifting tackle (optional), special
care must be exercised to prevent it from tipping. Additional safeguard-
ing measures must be taken. It is forbidden to pick up the robot in any
other way using a crane!
Fig. 6-3: Transportation by crane
1 Crane
2 Lifting tackle assembly (optional)
3 Link arm
4 Rotating column

Transportation KR AGILUS-2

KR AGILUS-2
Appendix
7 Appendix
7.1 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
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

Appendix KR AGILUS-2

KR AGILUS-2
KUKA Service
8 KUKA Service
8.1 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
8.2 KUKA Customer Support
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KR AGILUS-2

KR AGILUS-2
Index EC declaration of conformity......................... 14

EDS...................................................................6
2006/42/EC:2006.......................................... 125
Electromagnetic compatibility (EMC)........... 125
2014/68/EU:2014.......................................... 125
Electromagnetic compatibility (EMC):.......... 125
95/16/EC....................................................... 125
EMC Directive.................................................14
EN 60204-1:2006/A1:2009........................... 125
EN 61000-6-2:2005...................................... 125
A EN 61000-6-4:2007 + A1:2011.................... 125
Accessories................................................ 9, 13 EN 614-1:2006+A1:2009..............................125
AIR.................................................................... 6 EN ISO 10218-1:2011.................................. 125
Air consumption.......................... 28, 41, 55, 68 EN ISO 12100:2010..................................... 125
Air line connection...................... 28, 41, 55, 68 EN ISO 13849-1:2015..................................125
Angle of rotation............................................... 7 EN ISO 13849-2:2012..................................125
ANSI/RIA R.15.06-2012............................... 125 EN ISO 13850:2015..................................... 125
Appendix....................................................... 125 Energy supply system AIR CTR GIG..........114
Automatic mode..............................................24 Energy supply system CTR AIR.................. 112
Axis data, KR 10 R1100-2.............................69 ESD............................................. 29, 42, 56, 69
Axis data, KR 10 R900-2...............................56 Extension.......................................................... 6
Axis data, KR 6 R700-2.................................29 External axes..................................................13
Axis data, KR 6 R900-2.................................42 External axis...............................................8, 16
Axis limitation, mechanical............................. 18
Axis range.................................................. 6, 14
F
Faults.............................................................. 21
B Foundation loads, KR 10 R1100-2................ 78
Basic data, KR 10 R1100-2...........................67 Foundation loads, KR 10 R900-2..................65
Basic data, KR 10 R900-2.............................54 Foundation loads, KR 6 R700-2....................39
Basic data, KR 6 R700-2...............................28 Foundation loads, KR 6 R900-2....................52
Basic data, KR 6 R900-2...............................40 Function test................................................... 22
Brake defect................................................... 20
Brake release device......................................19
Braking distance.........................................6, 14
G
General information........................................ 83
General safety measures............................... 19
C GIG................................................................... 6
CE mark..........................................................14
Center of gravity...........................................121
Center of mass .......................... 33, 47, 60, 73
Certificates...................................29, 42, 56, 69
H
Handling equipment......................................122
Cleaning work.................................................25
Hazardous substances................................... 25
Compressed air...........................28, 41, 55, 68
Connecting cables....9, 13, 29, 42, 56, 69, 110
Counterbalancing system............................... 25
CTR...................................................................6 I
Industrial robot................................................13
Interface A1...................................................111
D Interface, energy supply system.................. 112
Interfaces...................................................... 110
Danger zone...............................................6, 15
Introduction....................................................... 5
Declaration of conformity............................... 14
Declaration of incorporation.....................13, 14
Decommissioning............................................26
Description, manipulator.................................10 K
Dimensions, transport...................................121 KCP......................................................7, 15, 20
Directives...................................................... 125 Keyboard, external......................................... 20
Disclaimer....................................................... 13 KL......................................................................7
Disposal.......................................................... 26 KR C................................................................. 7
Documentation, industrial robot....................... 5 KUKA Customer Support............................. 127
KUKA Service...............................................127
KUKA smartPAD....................................7, 9, 15
E KUKA smartPAD-2..................................... 7, 15

KR AGILUS-2
L Regulations................................................... 125
Labeling.......................................................... 19 Release device............................................... 19
Linear unit.......................................................13 Repair............................................................. 24
Low Voltage Directive.....................................14 Robot controller..........................................9, 13
M S
Machine frame mounting..............................108 Safety..............................................................13
Machinery Directive................................14, 125 Safety instructions............................................ 5
Main axes....................................................... 83 Safety of machinery..................................... 125
Maintenance................................................... 24 Safety options.................................................15
Manipulator......................................7, 9, 13, 15 Safety zone.............................................. 15, 17
Manual mode..................................................23 Safety, general................................................13
Mass............................................ 33, 47, 60, 73 Service life...................................................... 15
Mass moments of inertia............ 34, 48, 61, 74 smartPAD............................................. 7, 15, 20
Mechanical end stops.................................... 18 Software..................................................... 9, 13
MEMD............................................................... 7 Standards......................................................125
Misuse.............................................................11 Start-up........................................................... 21
Motion velocity..................................................7 STOP 0................................................ 7, 15, 83
Mounting base.............................................. 105 STOP 1................................................ 8, 15, 83
Mounting base with centering......................105 STOP 2...................................................... 8, 16
Mounting flange...........................35, 49, 62, 75 Stop category 0......................................... 7, 15
Mouse, external.............................................. 20 Stop category 1......................................... 8, 15
Stop category 2......................................... 8, 16
Stop category 1, Drive Ramp Stop............... 16
Stop signal......................................................83
O STOP 1 - DRS............................................... 16
Operators........................................................ 17 Stopping distance................................ 6, 14, 83
Options....................................................... 9, 13 Stopping distances......................................... 83
Overload......................................................... 20 Stopping distances, KR 10 R1100-2............. 98
Overpressure in the robot.......... 28, 41, 55, 68 Stopping distances, KR 10 R900-2............... 93
Overview of robot system................................ 9 Stopping distances, KR 6 R700-2................. 83
Stopping distances, KR 6 R900-2................. 88
Stopping time..................................................83
P Stopping times................................................83
Payload diagram......................... 34, 48, 61, 74 Stopping times, KR 10 R1100-2....................98
Payloads, KR 10 R1100-2............................. 72 Stopping times, KR 10 R900-2......................93
Payloads, KR 10 R900-2............................... 59 Stopping times, KR 6 R700-2........................83
Payloads, KR 6 R700-2................................. 32 Stopping times, KR 6 R900-2........................88
Payloads, KR 6 R900-2................................. 46 Storage........................................................... 26
Personal protective equipment...................... 16 Supplementary load.................... 37, 51, 64, 77
Personnel........................................................16 Support request............................................ 127
Phi.....................................................................7 System integrator.............................. 14, 16, 17
Planning........................................................ 105
Plant integrator............................................... 16
Plates and labels............................................80 T
Positioner........................................................ 13 T1 (operating mode).................................. 8, 16
POV.................................................................. 7 T2 (operating mode).................................. 8, 16
Pressure Equipment Directive............... 25, 125 Teach pendant............................................9, 13
Preventive maintenance work........................ 25 Technical data.................................................27
Product description...........................................9 Technical data, KR 10 R1100-2.....................67
Program override..............................................7 Technical data, KR 10 R900-2...................... 54
Protective equipment, overview..................... 17 Technical data, KR 6 R700-2........................ 28
PSA.................................................................16 Technical data, KR 6 R900-2........................ 40
Technical data, overview................................ 27
Terms used....................................................... 6
R Terms, safety.................................................. 14
RDC.................................................................. 7 Training............................................................. 5
Reaction distance.......................................6, 14 Transport position......................................... 121
Recommissioning............................................21 Transportation........................................ 21, 121

KR AGILUS-2
Turn-tilt table...................................................13
U
Use
Intended..................................................... 11
User.......................................................... 14, 16
Users.................................................................5
W
Warnings........................................................... 5
Workspace........................................... 6, 14, 17

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Robots

Publication: Pub Spez KR AGILUS-2 (PDF) en

Book structure: Spez KR AGILUS-2 V2.1

Version: Spez KR AGILUS-2 V5

2/131 | www.kuka.com Spez KR AGILUS-2 V5 | Issued: 07.12.2020

Spez KR AGILUS-2 V5 | Issued: 07.12.2020 www.kuka.com | 3/131

4.4.3 Payloads, KR 10 R900-2...................................................................................... 59

8 KUKA Service........................................................................................... 127

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1.1 Target group

This documentation is aimed at users with the following knowledge and

For optimal use of KUKA products, we recommend the training courses

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

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

Spez KR AGILUS-2 V5 | Issued: 07.12.2020 www.kuka.com | 5/131

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

edy emergencies or malfunctions:

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

1.4 Terms used

Stopping distance Stopping distance = reaction distance + braking distance

Extension Distance (l in %) between axis 1 and the intersection of axes 4 and

EDS Electronic Data Storage

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KL KUKA linear unit

KR C KUKA Robot Control

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

Manipulator The robot arm and the associated electrical installations

MEMD Micro Electronic Mastering Device

RDC Resolver Digital Converter

smartPAD Programming device for the robot controller

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

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)

T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

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2.1 Overview of the robot system

Fig. 2-1: Example of an industrial robot

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2.2 Description of the manipulator

The manipulators (= robot arm and electrical installations) of the variants

Fig. 2-2: Principal components

1 In-line wrist 4 Rotating column

In-line wrist – A4, A5, A6

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2.3 Intended use and misuse

Any use or application deviating from the intended use is deemed to be

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• Operation outside the specified operating parameters

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

The device described in this document is either an industrial robot or a

Information about safety may not be construed against the manufacturer.

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3.1.2 EC declaration of conformity and declaration of incorporation