BA - KUKA flexFELLOW - V03 - en PDF

KUKA flexFELLOW
Operating Instructions
Issue: V03-EN, 2016-08-31

Translation of the original German instructions
flexFELLOW
Manufacturer and distributor

KUKA Systems GmbH
Blücherstrasse 144
86165 Augsburg, Germany
Germany
© KUKA Systems GmbH 2016

The reproduction, transmission or use of this documentation or its contents is not
permitted without express written authority. Offenders will be liable to pay dam-
ages. All rights created by patent grant or registration of a utility model or design
are reserved.
Technical alterations:
Subject to technical alterations without an effect on the function.
II V03-EN, 2016-08-31
flexFELLOW Contents
Contents
Information about the operating instructions.................................................. 1
Target group ........................................................................................................ 1
Legal conditions................................................................................................... 1
Documentation for the KUKA flexFELLOW .......................................................... 1
Text conventions ................................................................................................. 1
Depiction of notes and symbols ....................................................................... 3
Warning against hazards ..................................................................................... 3
Terms used ......................................................................................................... 4
1 Safety .............................................................................................................. 1-1
1.1 Disclaimers ....................................................................................................... 1-1
1.2 Safety equipment and safeguards .................................................................... 1-2
1.2.1 Safety equipment .............................................................................................. 1-2
1.2.2 Safety measures............................................................................................... 1-2
1.2.3 Working areas and hazard areas ...................................................................... 1-3
1.3 Personnel ......................................................................................................... 1-3
1.4 Safety regulations ............................................................................................. 1-4
1.5 Safety instructions governing specific operating conditions .............................. 1-5
1.5.1 Commissioning ................................................................................................. 1-5
1.5.2 Maintenance and servicing ............................................................................... 1-5
1.6 Warning of special hazards............................................................................... 1-5
1.6.1 Electrical energy and electrical equipment ........................................................ 1-5
1.6.2 Pneumatic equipment ....................................................................................... 1-5
1.7 Restrictions on use ........................................................................................... 1-5
1.7.1 Intended use ..................................................................................................... 1-5
1.7.2 Improper use .................................................................................................... 1-6
2 Technical data................................................................................................. 2-7
2.1 Dimensions and weight..................................................................................... 2-7
2.2 Protection rating ............................................................................................... 2-7
2.3 Connection and operating data ......................................................................... 2-7
2.3.1 Electromagnetic compatibility (EMC) ................................................................ 2-8
2.4 Climatic conditions ............................................................................................ 2-8
3 Product description ........................................................................................ 3-1
3.1 Description ....................................................................................................... 3-1
3.2 View of the KUKA flexFELLOW ........................................................................ 3-2
3.3 Scope of supply ................................................................................................ 3-3
3.4 Rating plate ...................................................................................................... 3-4
3.5 Variants ............................................................................................................ 3-5
3.5.1 Function plate ................................................................................................... 3-5
3.5.2 Base unit .......................................................................................................... 3-6
V03-EN, 2016-08-31 III

Contents flexFELLOW
3.5.3 Pneumatic unit ..................................................................................................3-8

3.5.4 Fixed handle unit ...............................................................................................3-8
3.5.5 Height-adjustable handle unit ............................................................................3-9
3.5.6 Locking device (optional).................................................................................3-10
3.5.7 Safe monitoring of the lower handle position (optional) ...................................3-10
3.5.8 Stack lights......................................................................................................3-11
3.5.9 Transport unit without raise/lower facility .........................................................3-11
3.5.10 Transport unit without raise/lower facility (ESD) ..............................................3-11
3.5.11 Transport unit with raise/lower facility ..............................................................3-11
3.5.12 Transport unit with raise/lower facility (ESD) ...................................................3-11
3.5.13 Cooling unit with air conditioner .......................................................................3-12
3.5.14 Cooling unit with active fan ..............................................................................3-13
3.5.15 Connection interface X0 ..................................................................................3-13
3.5.16 Connecting cable ............................................................................................3-14
3.6 Optional components ......................................................................................3-15
3.6.1 Magnetic locking system .................................................................................3-15
3.6.2 Flange plate ....................................................................................................3-16
3.6.3 Mechanical locking system ..............................................................................3-18
3.6.4 Emergency Stop pushbutton ...........................................................................3-19
3.6.5 Laser scanner .................................................................................................3-20
3.6.6 Pneumatic components ...................................................................................3-21
3.7 Energy and power supply ................................................................................3-22
3.7.1 Service socket .................................................................................................3-22
3.7.2 Connector -X0 .................................................................................................3-23
4 Assembly and installation ..............................................................................4-1
4.1 Transporting and unpacking the packaged product ...........................................4-1
4.1.1 Transporting the packaged product ...................................................................4-1
4.1.2 Unpacking the packaged product ......................................................................4-1
4.2 Installation location ............................................................................................4-2
4.3 Transportation ...................................................................................................4-2
4.3.2 Transport by fork lift truck ..................................................................................4-3
4.3.3 Manual transport ...............................................................................................4-4
4.3.4 Height-adjustable handle unit ............................................................................4-6
4.4 Installing the stack lights ...................................................................................4-7
4.5 Installation .........................................................................................................4-9
4.5.1 Installation and alignment – without lowering device .........................................4-9
4.5.2 Installation and alignment – without locking device ...........................................4-9
4.5.3 Installation and alignment – with locking device ................................................4-9
4.6 Electrical installation ........................................................................................4-15
4.6.1 Connecting the equipotential bonding .............................................................4-15
4.7 Docking ...........................................................................................................4-16
4.7.1 Magnetic docking (optional).............................................................................4-16
IV V03-EN, 2016-08-31
flexFELLOW Contents
4.7.2 Mechanical docking (optional) ........................................................................ 4-17

4.8 Installation of the Emergency Stop button (optional) ....................................... 4-18
4.9 Installing the laser scanners (optional) ............................................................ 4-21
4.9.1 Installing a laser scanner on the intermediate plate ........................................ 4-21
4.9.2 Installing a laser scanner on the side mounting plate ...................................... 4-24
4.10 Installing robot components ............................................................................ 4-26
4.10.1 Installing the KUKA Sunrise Cabinet ............................................................... 4-26
4.10.2 KUKA Sunrise Cabinet interfaces ................................................................... 4-27
4.10.3 Connecting the KUKA smartPAD .................................................................... 4-29
4.10.4 Installing the robot .......................................................................................... 4-30
5 Operator control and operation ..................................................................... 5-1
5.1 Switching on KUKA flexFELLOW...................................................................... 5-1
5.2 Switching off KUKA flexFELLOW...................................................................... 5-1
6 Maintenance and servicing ............................................................................ 6-1
6.1 Cleaning and preventive maintenance .............................................................. 6-1
6.2 Preventive maintenance ................................................................................... 6-2
6.2.1 Exchanging the air filter .................................................................................... 6-2
6.3 Corrective maintenance .................................................................................... 6-2
6.3.1 Exchanging the rollers ...................................................................................... 6-2
6.3.2 Exchanging the stack lights .............................................................................. 6-3
6.3.3 Exchanging the covers on the function plate ..................................................... 6-5
6.3.4 Exchanging the side panel ................................................................................ 6-6
6.3.5 Exchanging the KUKA smartPAD holder .......................................................... 6-7
7 Decommissioning ........................................................................................... 7-1
7.1 Temporary decommissioning ............................................................................ 7-1
7.2 Corrosion protection and storage ...................................................................... 7-1
7.3 Disposal............................................................................................................ 7-2
8 Service and spare parts ................................................................................. 8-1
8.1 Service ............................................................................................................. 8-1
8.2 Spare parts ....................................................................................................... 8-1
8.3 Contact ............................................................................................................. 8-4
9 Declaration of Conformity .............................................................................. 9-1
10 Index ................................................................................................................... 1
V03-EN, 2016-08-31 V
flexFELLOW
VI V03-EN, 2016-08-31
flexFELLOW Information about the operating
instructions
Information about the operating instructions
In the following text the KUKA flexFELLOW is referred to either as the “KUKA
flexFELLOW” or as the “product”.
Target group
This documentation is aimed at users with the following knowledge and skills:
■ Advanced knowledge of mechanical engineering
■ Advanced knowledge of electrical and electronic systems
Legal conditions
The product described here is covered by Directive 2014/35/EU for electrical
equipment and has been checked according to UL 508 A for use in the United
States.
The declaration of conformity and all certificates issued with the product lose their
validity if additional components such as electrical components or controllers are
installed or robots incorporated.
Documentation for the KUKA flexFELLOW

The documentation for the KUKA flexFELLOW consists of:
■ These operating instructions
■ Operating instructions: Rittal cabinet fan (optional equipment)
■ Operating instructions: Rittal air conditioner (optional equipment)
■ Operating instructions: Ergoswiss hydraulic lifter (optional equipment)
■ Operating instructions: Leuze RSL 410 electronic safety laser scanner (op-
tional equipment)
This documentation is applicable to all components of the KUKA flexFELLOW.

The scope of supply of these operating instructions includes the operating in-
structions issued by the respective manufacturers for components that are incor-
porated.
Text conventions
Means of represen- Description
tation
 Indicates a work step that needs to be carried out
1. Indicate multiple work steps which you must perform in
2. the stated sequence
3.
■ Indicates a bullet point
This font Indicates terms and texts in a software user interface,
e.g.: Click on Save.
V03-EN, 2016-08-31 1
Information about the operating flexFELLOW
instructions
Means of represen- Description

tation
* Indicates optional machine equipment
2 V03-EN, 2016-08-31
flexFELLOW Depiction of notes and symbols
Depiction of notes and symbols

Warning against hazards
Safety instructions and warning notes indicate potential hazards when working
with the device.
Warnings with the signal words "DANGER", "WARNING", and "CAUTION" warn
of possible personal injury. Damage to property is given secondary consideration.
Warnings with the signal word "NOTICE" inform of potential damage to property
as a consequence of the hazard. There is no reason to expect personal injury.
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 instructions mean that damage to property may occur if no precautions
are taken.
Accompanying notes
Tip to make your work easier or reference to further information.
V03-EN, 2016-08-31 3
Depiction of notes and symbols flexFELLOW
Terms used
General terms used which are not company designations / type specifications.
Term Definition Explanation

KUKA smartPAD – Hand-held control panel for
robots
KUKA Sunrise – Robot controller
Cabinet
KUKA Sunrise.OS – System software for robots con-
trolled via a KUKA Sunrise Cab-
inet
4 V03-EN, 2016-08-31
Depiction of notes and symbols flexFELLOW
6 V03-EN, 2016-08-31
flexFELLOW Safety
1 Safety
1.1 Disclaimers
The product has been built in accordance with state-of-the-art standards and the
recognized safety rules. Nevertheless, its inadmissible misuse may constitute a
risk to life and limb, or cause damage to the product and other material property.
The product may be used only when in technically perfect condition, in accord-
ance with its intended use and only by safety-conscious persons who are fully
aware of the risks involved. These operating instructions must be complied with
in these respects. Any functional disorders, especially those affecting safety,
must be rectified immediately.
The operating company is responsible for complying with the national statutory
laws and regulations.
Safety information
Information about safety may not be construed against KUKA Systems GmbH.
Even if all safety instructions are followed, it cannot be ensured that the product
will not cause any injuries or damage.
No modifications may be made to the product without the permission of KUKA
Systems GmbH. It is possible for additional components not included in the
scope of supply of KUKA Systems GmbH to be integrated into the product. The
operating company is liable for any damage that occurs to the product or other
property as a result of these components.
External cross-references and links

KUKA Systems GmbH expressly disclaims all ownership of or responsibility for
the contents of any linked Web pages. This declaration applies to all external
links and Internet cross-references appearing in this documentation.
V03-EN, 2016-08-31 1-1

Safety flexFELLOW
1.2 Safety equipment and safeguards

1.2.1 Safety equipment
The product is fitted with the following safety equipment:
■ Secure stability in operation by means of a retractable hydraulic device
■ Enclosed and rounded edges
Optional:
■ Emergency Stop pushbutton
■ Laser scanners
■ Height-adjustable transport handle unit
■ Locking device for repeatable positioned installation with integrated safety
sensor in locked position
■ Stack lights for indicating operating states
In the absence of functional safety equipment, the product can cause personal in-
jury or material damage.
 Do not remove, deactivate or bypass any safety equipment.
 Before the product is started up, always check that all safety equipment is
operating correctly.
1.2.2 Safety measures

The safety integrator must integrate the product into the complete system in ac-
cordance with the safety requirements. The system integrator is responsible for
the following tasks:
■ Installing as well as safely securing the trolley.
■ Properly connecting all supply lines
■ Creating a risk assessment
■ Integration into the safety system
■ Creating an operating manual
■ Issuing a declaration of conformity and affixing the CE mark
If a laser scanner is installed:
■ Configuring the laser scanner
1-2 V03-EN, 2016-08-31

flexFELLOW Safety
1.2.3 Working areas and hazard areas
The system integrator is responsible for integrating the product into a system in
accordance with the safety requirements.
1.3 Personnel
Installation, exchange, setting, operation, maintenance and repair may be per-
formed only by personnel specially trained for the purpose and only as specified
in the operating instructions for the respective machine component.
All persons working with the product must have read and understood this docu-
mentation.
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Safety flexFELLOW
1.4 Safety regulations

The product may be used only when in technically perfect condition, in accord-
ance with its intended use and only by safety-conscious persons. Operator errors
can result in personal injury and damage to property.
 Avoid any operational mode that might be prejudicial to safety.

 Take the necessary precautions to ensure that the product is used only
when in a safe and reliable state!
 Operate the product only if all protective and safety-oriented devices are in
place and fully functional.
 In the event of malfunctions, stop the product immediately and lock it. Have
any defects rectified immediately.
 Make sure that any spare parts fitted comply with the technical require-
ments stipulated by the manufacturer. Spare parts from original equipment
manufacturers can be relied on to do so.
 Pneumatic hoses must be exchanged at appropriate intervals (after 6
years), even if no safety-relevant defects are evident (hose ageing).
 Adhere to prescribed intervals or those specified in the operating instruc-
tions for routine checks and inspections.
 For the execution of maintenance work, use tools and workshop equipment
adapted to the task on hand.
 Comply with local regulations (fire prevention instructions, etc.).
1-4 V03-EN, 2016-08-31

flexFELLOW Safety
1.5 Safety instructions governing specific operating conditions

1.5.1 Commissioning
 Before the product is put into operation, check that all protective devices
are complete and functioning correctly. Check all machine parts for the
presence of foreign bodies.
1.5.2 Maintenance and servicing

 Comply with the adjusting, maintenance and inspection activities and inter-
vals set out in the operating instructions, including information on the re-
placement of parts and equipment. These activities may be executed by
skilled personnel only.
 Clean the product, especially connections and threaded unions, of any
traces of oil, dirt, dust, swarf or preservatives before carrying out mainte-
nance/repair. Never use aggressive detergents. Use lint-free cleaning rags.
 Always retighten any screwed connections that were loosened during
maintenance and repair.
 Repair damage immediately.
 Following modifications or repairs, devices must be tested to ensure that
they are in a safe condition, or at least free of obvious damage or defects.
 Before commencing work on live parts, turn off the main switch and secure
it against being switched on again. Then verify isolation from voltage.
1.6 Warning of special hazards

1.6.1 Electrical energy and electrical equipment
 Use only original fuses with the specified current rating. Switch off the
product immediately if a malfunction occurs in the electrical system.
 Comply with all safety and danger signs on the electrical equipment.
 Work on electrical systems or equipment may be performed only by a quali-
fied electrician himself or by specially instructed personnel under the con-
trol and supervision of such an electrician and in accordance with the appli-
cable electrical engineering rules.
 Inspect and check the electrical equipment of the product at regular inter-
vals. Defects such as loose connections, abraded insulation or scorched
cables must be rectified immediately.
 Prevent the ingress of dirt (such as swarf and dust).
 If a particularly large amount of dirt or dust is created, cover the cabinet and
product.
1.6.2 Pneumatic equipment

Work on pneumatic equipment may be carried out only by persons having special
knowledge and experience of pneumatic systems.
1.7 Restrictions on use

1.7.1 Intended use
The KUKA flexFELLOW is a mobile unit in which electrical components are in-
stalled and on which an LBR iiwa robot system can be installed in accordance
V03-EN, 2016-08-31 1-5

Safety flexFELLOW
with its intended use. Installation space and connection options are provided in
the electrical enclosure for the required electrical components.
The following industrial robots may be mounted on the KUKA flexFELLOW and
operated on it:
■ KUKA LBR iiwa 7 R800
■ KUKA LBR iiwa 14 R820
The following items are not an integral part of the product:
■ Industrial robot
■ Sunrise Cabinet robot controller
■ KUKA smartPAD operator interface
■ Robot program
■ End effector
The product may be operated only when in technically perfect condition, in ac-
cordance with its intended use and only by safety-conscious persons who are ful-
ly aware of the risks involved.
Using the product for other or additional purposes is considered to be contrary to
its intended use. The manufacturer cannot be held liable for any damage result-
ing from such use.
1.7.2 Improper use

The product may not be operated in potentially explosive environments.
Any applications deviating from the intended use constitute impermissible mis-
use.
Misuse includes:
■ Transportation of persons and animals
■ Use as a climbing aid
■ Installation of industrial robots not listed as part of the intended use
■ Use outside the permissible, specified operating limits
■ Use in potentially explosive environments
■ Use outdoors or underground
■ Use without required additional safeguards
The manufacturer cannot be held liable for any damage resulting from such im-
proper use.
Any warranty granted on conclusion of the contract is rendered null and void in
the case of damage to the product resulting from:
■ Improper use of the product
■ Use of non-approved spare parts and wearing parts
■ Use of non-approved consumables, cleaning agents and other products
1-6 V03-EN, 2016-08-31

flexFELLOW Technical data
2 Technical data
2.1 Dimensions and weight
Designation Values
Length x Width x Height (without pneumatic 1000 mm x 630 mm x 760 mm
unit, lowered, without laser scanner)
Length x Width x Height (with pneumatic unit, 1000 mm x 630 mm x 910 mm
lowered, without laser scanner)
Floor space requirement approx. 1.0 m²
Weight incl. pneumatic module approx. 280 kg
2.2 Protection rating

Designation Values
Base unit IP54
USA: NEMA 1
Pneumatic unit (optional) IP20
USA: NEMA 1
2.3 Connection and operating data

The KUKA flexFELLOW may be connected only to a mains power supply with a
grounded neutral conductor.
Designation Values
Max. supply voltage 230 V ±10%
USA: 110 V ±10 %
Max. supply frequency 50 ±10 Hz
USA: 60 ±10 Hz
Rated input power 1 kVA, see rating plate
Max. power fuse of base unit FI/LS 16 A
USA: 15 A
Char. C 30 mA
Max. short-circuit current 10 kA
USA: SCCR 10 kA
Equipotential bonding The common neutral point for the
equipotential bonding conductors
and all protective earth conduc-
tors is the reference rail of the
power section.
Pneumatic unit (optional) Compressed air to ISO8573-1
quality class 3, max. 7 bar
V03-EN, 2016-08-31 2-7

Technical data flexFELLOW
A residual current circuit-breaker must be connected externally to the power

supply to the device (30 mA).
2.3.1 Electromagnetic compatibility (EMC)

If connecting cables (e.g. field buses, etc.) are routed from outside to the KUKA
flexFELLOW, only shielded cables with sufficient safeguarding may be used.
The KUKA flexFELLOW is intended for use in an industrial environment with a

Category C2 or C3 industrial network according to EN61800-3.
2.4 Climatic conditions

Designation Values
Ambient temperature during operation with +5 °C to +45 °C
air conditioner (not for USA) 278 K to 318 K
Ambient temperature during operation with +5 °C to 40 °C

active fan and USA 278 K to 313 K
Ambient temperature for storage and -25 °C to +40 °C
transport 248 K to 313 K
Rate of change of temperature max. 1.1 K/min
Humidity class 3k3 to DIN EN 60721-3-3; 1995
2-8 V03-EN, 2016-08-31

flexFELLOW Product description
3 Product description
3.1 Description
The KUKA flexFELLOW is a mobile unit in which electrical components are in-
stalled and on which an LBR iiwa robot system can be installed in accordance
with its intended use. Installation space and connection options are provided in
the electrical enclosure for the required electrical components. Drawers trolleys,
materials magazine trolleys and transport trolleys can optionally be included in
the scope of the product.
The KUKA flexFELLOW is available in two different versions:
■ Standard version
■ ESD version:
The ESD version has been developed for use with electrostatically sensi-
tive components. The rollers and the paint finish are of material compatible
with ESD components.
Details of the equipment of your KUKA flexFELLOW can be found in the scope
of supply and the parts list.
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Product description flexFELLOW
3.2 View of the KUKA flexFELLOW

The general setup of the KUKA flexFELLOW consists of 3 or 4 functional units
arranged one above the other:
■ Function plate with indicator lamp and handle
■ Pneumatic unit (optional)
■ Base unit
■ Transport unit
Function plate with

indicator lamp and handle
Pneumatic unit
Base unit
Transport unit
Fig. 1: General setup of the KUKA flexFELLOW
3-2 V03-EN, 2016-08-31

3.3 Scope of supply

The KUKA flexFELLOW is available in various different versions. Details of the
equipment of your KUKA flexFELLOW can be found in the scope of supply and
the parts list.
The following modules are part of the KUKA flexFELLOW modular system:
■ Packaging
■ Documentation
■ Base unit
■ Stack lights
■ Transport unit in different variants
■ Handle unit
■ Cooling unit in different variants
■ Energy interface in different variants
■ KUKA smartPAD holder
■ Electrical components
■ Mechanical locking system
■ Magnetic locking system
■ Height-adjustable handle with locking device and floor sockets: the lower han-
dle position is monitored (inductive safety sensor)
■ Drilling template
■ Pneumatic unit
■ Laser scanner
■ Pneumatic components
■ Additional Emergency Stop button on function plate
■ Locking system with hole pattern
■ Start-up connector
■ Application package (I/O module)
■ Connecting cable X650/651
V03-EN, 2016-08-31 3-3

3.4 Rating plate
Fig. 2: KUKA flexFELLOW rating plate acc. to Low-Voltage Directive and

CE label
3-4 V03-EN, 2016-08-31

3.5 Variants
The modular design of the KUKA flexFELLOW, with the associated variants and
options, allows a variety of different configurations.
Details of the equipment of your KUKA flexFELLOW can be found in the scope
of supply and the parts list.
3.5.1 Function plate
1
1
1 1
Fig. 3: View of the KUKA flexFELLOW function plate

1. Cover plate (optional for stack lights or Emergency Stop)
2. Hole pattern for robot with mounting plate (on left or right as desired)
The KUKA flexFELLOW function plate serves the purpose of mounting the robot
unit, the stack lights with the KUKA smartPAD holder and the optional Emergen-
cy Stop button. The function plate offers various adaptation options for applica-
tion-specific attachments.
The hole patterns for mounting the KUKA LBR iiwa 7 R800 or KUKA LBR iiwa 14
R820 are provided in the mounting plate.
V03-EN, 2016-08-31 3-5

3.5.2 Base unit

The base unit of the KUKA flexFELLOW contains various energy interfaces, the
locking system (e.g. mechanical or magnetic) and a cooling unit.
The control elements, energy interfaces and connectors are mounted on the door
side of the base unit.
1
5
7
4
8
9
2
10
Fig. 4: View of the door side of the KUKA flexFELLOW
No. Description
1 Main switch with Emergency Stop function
2 Control cabinet lock: a control cabinet key can be used to open these
locks and thereby open the control cabinet door.
3 Crank: if the option for lowering the transport unit is fitted, the transport
rollers of the KUKA flexFELLOW can be raised and lowered.
4 Locking system (mechanical or magnetic) or mounting plate for laser
scanner
5 Connectors and interfaces:
■ Service socket
■ USB connection to the Sunrise controller
■ Network connection to the Sunrise controller
3-6 V03-EN, 2016-08-31

No. Description
6 Connection interface (connector X0): modular plug for connecting vari-
ous media to the KUKA flexFELLOW:
■ Power
■ Air
■ Safety signals
■ Network equipment
7 Energy interface: power supply for external devices on an additional
trolley
8 Buzzer (freely programmable acoustic warning signal)
9 Connection socket for KUKA smartPAD
10 Socket for connection of equipotential bonding
A printout of the circuit diagrams is located on the side, inside the control cabinet
door.
Fuses:
Fuse Description
F1 Socket
F2 24 V
F3 Robot controller
F4 Air conditioner
F11 24 V control voltage, internal
F12 24 V control voltage, external
V03-EN, 2016-08-31 3-7

3.5.3 Pneumatic unit
Fig. 5: KUKA flexFELLOW pneumatic unit
An optional pneumatic unit is located between the base unit and the function
plate. User-specific pneumatic modules can be installed in this area.
If the trolley is equipped with pneumatic devices, power for them will be supplied
via connector X0. Optional components: The digital pressure display indicates
the pressure set on the pressure regulator. An additional manometer is installed
on the pressure reducer. The pneumatic unit provides air to pneumatic tools
which can be optionally installed on the robot. A valve for switching the consum-
ers is not provided and can be retrofitted.
The KUKA flexFELLOW should be supplied with compressed air to ISO8573-1,

quality class 3 and max. 7 bar.
3.5.4 Fixed handle unit

The handle unit allows the KUKA flexFELLOW to be moved to another location.
The handle unit is fixed, its height cannot be adjusted.
3-8 V03-EN, 2016-08-31

3.5.5 Height-adjustable handle unit

The handle unit allows the KUKA flexFELLOW to be moved to another location.
The handle unit is height-adjustable and lockable. The lower handle position is
monitored by a safety sensor.
Fig. 6: View of the KUKA flexFELLOW function plate

1. Handle
2. Release button for height-adjustable handle
V03-EN, 2016-08-31 3-9

3.5.6 Locking device (optional)
1 1
2 2
Fig. 7: KUKA flexFELLOW locking device
1. Adjustable feet
2. Locking device
For placing the product at a defined position, it is equipped with an integrated

locking device which allows for exact and repeatable positioning of the KUKA
flexFELLOW. The KUKA flexFELLOW achieves this locking function by means of
extendable pins and sword pins on the underside of the trolley which engage in
sockets appropriately positioned on the floor. A KUKA flexFELLOW with a locking
device always has a height-adjustable handle unit. The height-adjustable handle
unit also serves as an operating element for the locking device.
The floor sockets are bonded in the desired positions and with a defined spacing.
A drilling and bonding template is optionally available as a positioning aid for drill-
ing the holes as well as for bonding the sockets.
3.5.7 Safe monitoring of the lower handle position (optional)

An integrated sensor (optional) detects the lowest position of the handle and thus
the safely locked state (locked and lowered). The signal may be used optionally.
DANGER Check the safety functions!

Optional safety components, such as the Emergency Stop button, the laser
scanners and the locking device, are not included in the standard safety configu-
ration and are thus not operational.
The KUKA flexFELLOW must not be put into operation if safety functions or
safeguards are disabled or removed.
3-10 V03-EN, 2016-08-31

3.5.8 Stack lights

The stack lights can be installed at all 4 corners of the function plate. They serve
to indicate the operating states of the optionally installed robot system.
3.5.9 Transport unit without raise/lower facility

The transport unit without raise/lower facility consists of 4 castors (Ø 75 mm) with
locking brakes. The rollers are intended for relocating the trolley over short dis-
tances and for precise adjustment of the position. Fork slots are provided for
transport over longer distances.
3.5.10 Transport unit without raise/lower facility (ESD)

The transport unit without raise/lower facility (ESD) has been developed for use
with electrostatically sensitive components. The rollers and the paint finish are of
material compatible with ESD components.
The transport unit without raise/lower facility consists of 4 castors (Ø 75 mm) with
locking brakes. The rollers are intended for relocating the trolley over short dis-
tances and for precise adjustment of the position. Fork slots are provided for
transport over longer distances.
3.5.11 Transport unit with raise/lower facility

The transport unit with raise/lower facility consists of 4 castors (Ø 60 mm). The
rollers are intended for relocating the trolley over short distances and for precise
adjustment of the position. Fork slots are provided for transport over longer dis-
tances. A crank allows the KUKA flexFELLOW to be lowered for better stability.
When the KUKA flexFELLOW is lowered it stands on the floor on 4 machine feet.
2 of the machine feet are height-adjustable to ensure the product stands securely
on uneven floors without any risk of toppling.
3.5.12 Transport unit with raise/lower facility (ESD)

The transport unit with raise/lower facility (ESD) has been developed for use with
electrostatically sensitive components. The rollers and the paint finish are of ma-
terial compatible with ESD components.
The transport unit with raise/lower facility consists of 4 castors (Ø 60 mm). The
rollers are intended for relocating the trolley over short distances and for precise
adjustment of the position. Fork slots are provided for transport over longer dis-
tances. A crank allows the KUKA flexFELLOW to be lowered on to its frame for
better stability. When the KUKA flexFELLOW is lowered it stands on the floor on
4 machine feet. 2 of the machine feet are height-adjustable to ensure the product
stands securely on uneven floors without any risk of toppling.
V03-EN, 2016-08-31 3-11

3.5.13 Cooling unit with air conditioner
The air conditioner described here is not available for the American market.
Fig. 8: KUKA flexFELLOW cooling unit
1. Air conditioner
The KUKA flexFELLOW is equipped with a Rittal SK 3302.100 air conditioner for
cooling the control cabinet. The openings of the air conditioner must not be ob-
structed at the site of installation. A distance of at least 150 mm from the nearest
component must be maintained. The quantity of condensate is minimal and is
discharged via a hose on to the floor.
The thermostat of the air conditioner is preset to a temperature of 25 °C.
3-12 V03-EN, 2016-08-31

3.5.14 Cooling unit with active fan

The KUKA flexFELLOW is equipped with a Rittal SK 3241.124 filter fan and air
outlet for cooling the control cabinet.
The thermostat of the filter fan is preset to a temperature of 25 °C.
3.5.15 Connection interface X0
Fig. 9: KUKA flexFELLOW connector X0
1. Module F: -X0F, EtherCAT interface

2. Module E: dummy module (not assigned)
3. Module D: -X0D, spare 24 V
4. Module C: -X0C, 6 bar air interface (only with optional pneumatic unit)
5. Module B: -X0B, safety signal interface
6. Module A: -X0A, 230 V interface (USA: 115 V)
The KUKA flexFELLOW is supplied with electrical and pneumatic energy via
connector X0. Safety and EtherCat signals are, if required, also routed through
connector X0. The connector is assigned as the energy, logic and pneumatic in-
terface (for the variant with a pneumatic unit) and also for the external operator
safety signal.
The wiring of the mating connector is not included in the KUKA scope of supply
and must be carried out by a qualified electrician in accordance with the applica-
ble local regulations.
A suitable mating connector is available from KUKA as an accessory.
V03-EN, 2016-08-31 3-13

3.5.16 Connecting cable
The connecting cable is not included in the KUKA scope of supply and must be
connected by a qualified electrician in accordance with the applicable local regu-
lations.
The following minimum requirements must be observed:
■ Wire number and cross section: 3G2.5 mm² AWG 14

■ Conductors: fine-wired, uninsulated copper strands acc. to IEC 60228, Class 5
■ Wire insulation + outer sheath: PVC mixture (UL/CSA 90°C rating)
■ Flammability: acc. to IEC 60332-1-2; UL: Cable flame test, VW-1
3-14 V03-EN, 2016-08-31

3.6 Optional components

The following optional components are possible on the corner posts of the KUKA
flexFELLOW:
■ Magnetic locking system
■ Flange plate or grid plate (e.g. for mounting a laser scanner)
■ Mechanical locking system
3.6.1 Magnetic locking system
Fig. 10: Position of the KUKA flexFELLOW magnetic locking system
The magnetic locking system can be used to dock the KUKA flexFELLOW to
other trolleys in the system.
The magnets are only suitable for connecting the product to elements intended
for this purpose. The counterpart to the magnets should be a steel plate at least
15 mm thick, matching the dimensions of the magnet and aligned such that it al-
ways fully contacts the face of the magnet.
V03-EN, 2016-08-31 3-15

3.6.2 Flange plate
Fig. 11: Position of the KUKA flexFELLOW flange plates
Additional optional components can be mounted on the flange plate, e.g. a me-
chanical locking system or a laser scanner.
Hole pattern of the flange plate
6x M8
(max. length of engagement:
15mm)
Aperture 21
(optional knock-out
design)
Fig. 12: Flange plate
3-16 V03-EN, 2016-08-31

Load limits of the flange plate
Fig. 13: Forces acting on the flange plate
1. Tensile force Fx
2. Tensile force Fy
3. Tensile force Fz
4. Torque Mk
Load limits of the flange plate:

■ Fx max. 200 N
■ Fy max. 200 N
■ Fz max. 200 N
■ Mk max. 80 Nm
V03-EN, 2016-08-31 3-17

3.6.3 Mechanical locking system
Fig. 14: Position of the KUKA flexFELLOW mechanical locking system
The mechanical locking system can be used to attach the KUKA flexFELLOW to
other trolleys in the system.
The mechanical locking system is only suitable for connecting the product to el-
ements intended for this purpose.
3-18 V03-EN, 2016-08-31

3.6.4 Emergency Stop pushbutton
Fig. 15: Emergency Stop pushbutton
The KUKA flexFELLOW can optionally be equipped with an Emergency Stop but-
ton. The Emergency Stop button is connected to the KUKA flexFELLOW via a
connecting cable.
There are 4 installation options for the Emergency Stop button on the function
plate of the KUKA flexFELLOW.

V03-EN, 2016-08-31 3-19

3.6.5 Laser scanner
Fig. 16: RSL 410 safety laser scanner
The KUKA flexFELLOW can optionally be equipped with up to 2 RSL 410 safety
laser scanners from Leuze electronic. The laser scanners are connected to the
KUKA flexFELLOW via plug-in connectors.
There are mounting options for laser scanners on the grid plates at all 4 corners
or on the function plate of the KUKA flexFELLOW.

3-20 V03-EN, 2016-08-31

Fig. 17: Installation location for laser scanners
3.6.6 Pneumatic components

The optional pneumatic equipment consists of a drawer for mounting the pneu-
matic components and a basic installation consisting of:
■ 1x service unit
■ 1x pressure switch with pressure indicator
■ 1x shut-off valve
(see pneumatic diagram in annex)
V03-EN, 2016-08-31 3-21

3.7 Energy and power supply

connector X0.
3.7.1 Service socket

The service socket on the KUKA flexFELLOW is intended for connecting a laptop
or PC for general tasks or service work on the Sunrise controller. The operation
of other devices (such as drills, angle grinders or cutters or recreational equip-
ment such as radios, coffee machines, etc.) is not permitted.
The socket is closed with a flap to prevent accidental contact.
Fig. 18: Service socket
1. Service socket
DANGER Risk of fatal injury from electric shock!

The service socket has no ground conductor.
 Connect only double-insulated devices of protection class II to the service
socket.
 Ensure that the prescribed residual current circuit-breaker is connected up-
stream of the KUKA flexFELLOW (see Section 2.3 Connection and operating
data).
USB and Ethernet interfaces serve for easy access when programming or for
servicing.
3-22 V03-EN, 2016-08-31

3.7.2 Connector -X0

connector X0. Safety and EtherCat signals are, if required, also routed through
connector X0.
Connector -X0A
■ Electrical ratings: 230 VAC, 50 Hz, 16 A
■ Electrical ratings USA: 110 VAC, 60 Hz, 15 A
■ Ground conductor
1
Fig. 19: Connector -X0A
1. KUKA scope of supply

2. Connecting cable provided by customer
V03-EN, 2016-08-31 3-23

Connector -X0B
Safety interface:
■ Internal safety signals (Emergency Stop, handle monitoring, scanner) are pre-
wired via terminal strip X11.1.
■ External safety signals are pre-wired via connector -X0B and terminal strip
X11.1.
Pre-wired safety signals

Inputs:
Signal Symbol Description Condition on delivery
Input 1 CIB SR.1 Additional Emergency Pre-wired to X11.1
Stop
Input 2 CIB SR.2 Operator safety han- Pre-wired to X11.1
dle locked
Input 3 CIB SR.3 External operator Pre-wired to connector X0B
safety
Input 4 CIB SR.4 External Emergency Pre-wired to connector X0B
Stop
Input 5 CIB SR.5 Scanner 1 Pre-wired to X11.1
Input 6 CIB SR.6 Scanner 2 Pre-wired to X11.1
Input 7 CIB SR.7 Spare Pre-wired to X11.1
Outputs:
Signal Symbol Description Condition on delivery
Output 1 CIB SR.12 Emergency Stop to Pre-wired to X11.1
external
Output 2 CIB SR.13 Spare Pre-wired to X11.1
Output 3 CIB SR.14 Spare Pre-wired to X11.1
3-24 V03-EN, 2016-08-31

Wiring diagram X11.1
Fig. 20: Wiring diagram X11.1
V03-EN, 2016-08-31 3-25

Connector -X0F
■ EtherCat interface
The KUKA Extension Bus (-X65) can be extended via connector X0F.
Fig. 21: Connector -X0F
3-26 V03-EN, 2016-08-31

V03-EN, 2016-08-31 3-27

flexFELLOW Assembly and installation
4 Assembly and installation

4.1 Transporting and unpacking the packaged product
The product is delivered with padding in a cardboard box. The cardboard box is
mounted on a Euro pool pallet and secured with two lashing straps.
Fig. 22: Packaged product
4.1.1 Transporting the packaged product

1. Fully insert the forks into the Euro pool pallet.
2. Secure the product against sliding off. The trolley without robot and control-
ler, including the pneumatic module and the packaging, weighs approx.
310 kg.
4.1.2 Unpacking the packaged product
NOTICE Risk of damaging the product!

Cutting open the cardboard box risks scratching or damaging the product.
 Do not cut open the cardboard box.
1. Cut both the lashing straps with a sharp tool (such as a box cutter).
2. Remove the corner pads and cardboard ring.
3. Remove the film, padding material and loose parts.
4. Bend the corners of the base of the cardboard box out so that the fork slots
in the base frame of the product are freely accessible.
5. Use a fork lift truck to lift the product off the Euro pool pallet, see 4.3.2
Transport by fork lift truck.
V03-EN, 2016-08-31 4-1

Assembly and installation flexFELLOW
4.2 Installation location

Condition of floor surface
The manufacturer recommends a painted concrete floor, which can easily be
brushed clean of dust.
4.3 Transportation
The product can be transported by means of a fork lift truck or manually on its
castors. Manual transport is only intended for relocating the product over short
distances and for precise adjustment of the position. Over longer distances ideal-
ly the product should be transported by fork lift truck.
CAUTION Toppling/crushing hazard!

If a robot system is mounted on the KUKA flexFELLOW, the KUKA flexFELLOW
may topple over and cause injuries to personnel.
 Move the robot into a suitable transport position.
 Make sure that the center of gravity of the robot lies above the trolley.
 Make sure that no part of the robot projects beyond the trolley.
4-2 V03-EN, 2016-08-31

4.3.2 Transport by fork lift truck

The underside of the product is equipped with fork slots by which the trolley can
be lifted and transported.
1. The forks must be fully inserted into the fork slots in the base frame of the
product.
2. Secure the product against sliding off. Observe the weight of the trolley with
robot and controller, including the pneumatic module (see rating plate).
1
1
Fig. 23: Fork slots
1. Fork slots; 2 per side
V03-EN, 2016-08-31 4-3

4.3.3 Manual transport
CAUTION Toppling/crushing hazard!

If the wheels are jammed the product is liable to topple and cause injuries to
personnel.
 Make sure that no dirt or foreign bodies can jam the wheels.
For use when moving the product manually over short distances and for precise
adjustment of the position, it is fitted with four castors.
Optionally these can be housed out of sight within the transport unit. In this ver-
sion, a hand crank for extending the castors is located on the service panel.
Version with lowering function

1. Fold out the crank and turn it until the trolley is standing freely on the cas-
tors. The four castors are extended/retracted simultaneously.
2. For transport, fold the crank away again.
Fig. 24: KUKA flexFELLOW hand crank and castors
1. Hand crank
2. Castors
4-4 V03-EN, 2016-08-31

Raising and lowering the KUKA flexFELLOW with the raise/lower facility
1. Fold out the hand crank.
2. Turn the hand crank so as to raise or lower the trolley.
When transporting the KUKA flexFELLOW using the castors, they must be fully
extended.
3. Fold away the hand crank.
Version without lowering function

1. Release the locking brake.
V03-EN, 2016-08-31 4-5

4.3.4 Height-adjustable handle unit

The trolley has the option of a steplessly height-adjustable handle unit.
Fig. 25: Height-adjustable handle unit
1. Height-adjustable handle unit

2. Locking button
Adjusting the height-adjustable handle unit

1. Press the locking button (2) and hold it down.
2. Adjust the height of the handle unit (1).
3. Release the locking button (2).
4-6 V03-EN, 2016-08-31

4.4 Installing the stack lights
Fig. 26: Installing the stack lights
1. Place the stack lights (1) on the function plate. When doing so, make sure
that the holes for the stack light screws line up with the tapped holes in the
function plate.
2. Attach the stack lights with four M6x20 ISO14581 screws (2).
3. Connect the stack lights in accordance with the following connection dia-
gram and reconnect M8 connector to cable.
V03-EN, 2016-08-31 4-7

Fig. 27: Circuit diagram for the stack lights
4-8 V03-EN, 2016-08-31

4.5 Installation
4.5.1 Installation and alignment – without lowering device
In order to ensure stability of the KUKA flexFELLOW, the locking brakes of the
castors must be applied.
Before putting the product into operation at a new location the stability must be
checked. The KUKA flexFELLOW must stand stably on all 4 castors and also be
secured.
4.5.2 Installation and alignment – without locking device

When the castors are retracted, the KUKA flexFELLOW stands on the floor at 4
points, of which 2 are implemented as height-adjustable feet to ensure the KUKA
flexFELLOW stands securely and without any risk of toppling over, even on une-
ven floors.
Before putting the product into operation at a new location the stability must be
checked. If necessary, the height of the machine feet must be adjusted using the
screw threads and an open-end wrench.
4.5.3 Installation and alignment – with locking device
1
1
2
2
Fig. 28: KUKA flexFELLOW locking device
1. Adjustable feet
2. Locking device
The locking device allows the KUKA flexFELLOW to be locked at a fixed position
by means of extendable pins.
V03-EN, 2016-08-31 4-9

Installing floor sockets for the locking device
A drilling and bonding template is available as a template for drilling the holes as
well as for bonding the floor sockets (optional scope of supply).
5
3
4
3
1
5
Fig. 29: Installing floor sockets using a drilling template
1. Drilling template
2. Drill bushing
3. Centering pin
4. Retaining hole for aligning the drilling template
5. Hole for the floor socket
Attaching the drilling template:

1. Mark the desired position of the KUKA flexFELLOW (lines).
2. Mark the locations of the holes as defined by the drilling template.
Distance between holes: 328 mm
Retaining hole for drilling template located centrally between the holes
3. Drill the retaining hole.
Hole diameter: 8 mm; hole depth: 50 mm
4. Clean out the retaining hole using a wire brush, vacuum cleaner or com-
pressed air.
5. Insert a universal plug (e.g. Fischer UX8x40, not in scope of supply) in the
retaining hole.
6. Place the drilling template on the floor over the retaining hole.
7. Place a washer on a screw and insert the screw through the opening for the
retaining hole (4) into the floor plug, but do not fully tighten it.
8. Align the drilling template, hold it in position and tighten the screw in the re-
taining hole.
4-10 V03-EN, 2016-08-31

V03-EN, 2016-08-31 4-11

Drilling the holes for the floor sockets:

1. Insert the drill bushings (2) into the drilling template to serve as a guide.
2. Drill the centering holes.
Diameter: 8 mm; hole depth: approx. 50 mm
3. Release the drilling template (1) from the floor and remove it.
4. Rebore the centering holes for the floor sockets.
Diameter: 38 mm; hole depth: 40 mm
5. Clean out the holes using a wire brush, vacuum cleaner or compressed air.
Individual parts of the floor socket
Fig. 30: Individual parts of the floor socket
6. Upper part
7. Dust shield
8. Spring
9. Floor socket
4-12 V03-EN, 2016-08-31

Bonding the floor sockets in the floor:
2
3
Fig. 31: Turning over the drilling template
1. Drilling template
2. Drill bushing
3. Centering pin
1. Insert centering pins (3) into drilling template (1) and turn over drilling tem-
plate.
1. Using a suitable applicator gun, fill both holes with approx. 25 ml (25 cm³) of
injection resin (HIT-RE 500).
2. Press the floor sockets into the two holes.
3. Remove excess injection resin.
4. Insert the drilling template (1) with centering pins (3) into the floor sockets,
thereby establishing the precise spacing of the floor sockets (328 mm).
5. Carefully remove the drilling template.
6. Allow the injection resin to cure (approx. 12–24 h).
V03-EN, 2016-08-31 4-13

Positioning and locking the KUKA flexFELLOW

1. Extend the KUKA flexFELLOW castors and move it so that it is positioned
over the floor sockets.
2. Position the ends of both handle bars exactly over the floor sockets.
3. Release the height adjustment lock.
4. Push the handle unit to its lowest position.
The sword pins and pins extend from the KUKA flexFELLOW during the
motion and can thus engage in the floor sockets.
5. Use the hand crank to retract the castors.
An integrated safety sensor detects the lowest position of the handle and
thus the safely locked state (locked and lowered). The signal may be used
optionally.
6. Adjust the machine feet to achieve a stable trolley position.

For details of exchanging the hand crank of the hydraulic lifting unit, see the Er-
goswiss operating instructions.
4-14 V03-EN, 2016-08-31

4.6 Electrical installation

See Section 2.3 Connection and operating data for the technical specifications.
1. Equip the supply connection with slow-blow fuses of max. 16 A (USA 15 A).
2. Connect the KUKA flexFELLOW using connector X0, see 3.7.2 Connector -
X0.
4.6.1 Connecting the equipotential bonding
Fig. 32: Equipotential bonding
1. Socket for equipotential bonding

1. Insert the equipotential bonding cable into the equipotential bonding socket
(1).
2. Connect the equipotential bonding cable to the ground potential.
The wiring of the mating connector is not included in the KUKA scope of supply
and must be carried out by a qualified electrician in accordance with the applica-
ble local regulations.
A suitable mating connector is available from KUKA as an accessory.
V03-EN, 2016-08-31 4-15

4.7 Docking
4.7.1 Magnetic docking (optional)
1 1
Fig. 33: KUKA flexFELLOW magnetic locking system
1. Locking magnet
The locking magnets serve for docking the KUKA flexFELLOW to the system or
to another trolley belonging to the system.
The magnets are only suitable for connecting the product to elements intended
for this purpose. The counterpart to the magnets must be a steel plate at least
15 mm thick, matching the dimensions of the magnet and aligned such that it al-
ways fully contacts the face of the magnet.
The magnets may only be turned on if the magnet surface is in direct contact with
the counterpart. In particular, no tools or other metal objects may be in the vicinity
of the face of the magnets when they are switched on.
WARNING Crushing hazard!

When the magnets are switched on there is a crushing hazard between the two
trolleys or between the trolley and the system that are being docked to each oth-
er.
 Keep a safe distance from the trolley or the system.
The magnets are powered by direct current. They pose no hazard to persons
with cardiac pacemakers.
The controller can be used to monitor whether the locking element has docked
with a mating part.
4-16 V03-EN, 2016-08-31

Strong vibrations, collisions, etc., can cause the relative positions of the elements
to one another to change. In order to ensure maximum holding force and safety,
check the following:
■ The trolleys are correctly installed.
■ The elements have been positioned correctly relative to one another.
■ If the positions have changed slightly, collisions cannot occur during automatic
operation of the overall system (check programming of the robot arm and
adapt if necessary).
4.7.2 Mechanical docking (optional)
2
1
3
Fig. 34: KUKA flexFELLOW mechanical locking system
1. Mating part of the mechanical locking system

2. Locking button
3. Mechanical locking system
The mechanical locking system can be used to dock the KUKA flexFELLOW to
the system or to another trolley in the system.
1. Pull out the locking knob.
2. Turn the locking knob to lock it in the open position.
3. Push the product with mating part into the mechanical locking system.
4. Position the product with mating part so that the locking pin fits into the slot
on the mating part.
5. Turn the locking knob until it locks in place.
V03-EN, 2016-08-31 4-17

4.8 Installation of the Emergency Stop button (optional)

During configuration of the KUKA flexFELLOW, one of the 4 possible installation
positions for the Emergency Stop button on the function plate was selected. The
position is indicated by the hole in the cover plate and by the connecting cable.
Fig. 35: Removing the cover plate with the hole
4-18 V03-EN, 2016-08-31

Fig. 36: Assembling the Emergency Stop pushbutton
1. Emergency Stop pushbutton

2. Cover plate for Emergency Stop pushbutton
3. Fastening nut
Before the Emergency Stop button is assembled, it must be wired according to

the following connection diagram by a qualified electrician. The push-in sleeves
must be pushed onto the corresponding contacts of button -S21 and then fitted
with an insulating sleeve.
Fig. 37: Connection diagram for Emergency Stop pushbutton
V03-EN, 2016-08-31 4-19

Fig. 38: Screw-fastening the Emergency Stop pushbutton

4-20 V03-EN, 2016-08-31

4.9 Installing the laser scanners (optional)

During configuration of the KUKA flexFELLOW, the possible installation positions
for the laser scanners were selected. The preinstalled connecting cables and
connectors for the laser scanners are located here.
Mounting points for laser scanners:
■ on the function plate next to the robot arm
■ on the mounting plate at the corner of the KUKA flexFELLOW

4.9.1 Installing a laser scanner on the intermediate plate
Fig. 39: Installing the mounting bracket
1. Place the mounting bracket on the intermediate plate and firmly screw it on
with 3 screws.
2. Connect the connecting cable to the laser scanner.
V03-EN, 2016-08-31 4-21

Fig. 40: Installing the laser scanner
1. Screw the laser scanner to the mounting bracket with 4 screws.
Fig. 41: Fitting the cover
2. Place the cover on the laser scanner.
4-22 V03-EN, 2016-08-31

Fig. 42: Screwing on the cover
3. Screw on the cover with 4 screws.
V03-EN, 2016-08-31 4-23

4.9.2 Installing a laser scanner on the side mounting plate
Fig. 43: Installing the holder
1. Screw the holder onto the mounting plate with 2 screws.
Fig. 44: Mounting the lower hoop guard
2. Screw on the lower hoop guard with 2 screws.
4-24 V03-EN, 2016-08-31

Fig. 45: Mounting the upper hoop guard
3. Screw on the upper hoop guard with 2 screws.

4. Connect the connecting cable (scope of supply) to the laser scanner.
Installation prepared
Fig. 46: Installing the laser scanner
5. Screw on the laser scanner with 4 screws.
V03-EN, 2016-08-31 4-25

4.10 Installing robot components

The following components are not part of the scope of supply of the KUKA flex-
FELLOW. See Section 3.3 Scope of supply.
4.10.1 Installing the KUKA Sunrise Cabinet

1. Release the 2 fasteners of the rear side panel.
2. Remove the side panel.
3. Align the Sunrise Cabinet so that the door faces the side panel.
1
1
1
1
Fig. 47: Installing the KUKA Sunrise Cabinet
1. Threaded bolt
4. Hook the Sunrise Cabinet onto the threaded bolts (1).
5. Screw the Sunrise Cabinet onto the threaded bolts with 4 washers and nuts.
6. Connect all cables to the corresponding mating parts.
7. Screw the PE conductor firmly in place with the corresponding screw.
8. Refit the side panel.
9. Secure the side panel with the 2 fasteners.
4-26 V03-EN, 2016-08-31

4.10.2 KUKA Sunrise Cabinet interfaces
Fig. 48: KUKA Sunrise Cabinet interfaces
No. Designation No. Designation

PE PE connections X69 Service interface
X1 Power supply connection X65 Extension interface
X66 KUKA line interface X19 smartPAD interface
X21 Manipulator interface X11 Interface
X650 Media flange interface 1 Control PC interfaces
X76/X Media flange interface X31 KUKA system cable type
651 X21/X31 interface
Interface cables prepared in the KUKA flexFELLOW:

■ –WX65
■ –WX66
■ –WXUSB
■ –WP_10 (to –X19)
■ –X11.1 to –X11
Connection cables from the Sunrise Cabinet to the robot:
■ –WX21X31
■ –WX650X651
 Connect the prepared interface cables and connecting cables as shown in
the circuit diagram below.
V03-EN, 2016-08-31 4-27

Fig. 49: Circuit diagram of interfaces
4-28 V03-EN, 2016-08-31

4.10.3 Connecting the KUKA smartPAD
Fig. 50: Connecting the KUKA smartPAD
1. Connection socket for KUKA smartPAD

 Insert the KUKA smartPAD connector into the KUKA smartPAD connection
socket (1).
V03-EN, 2016-08-31 4-29

4.10.4 Installing the robot

1. Place the intermediate plate (“robot mounting plate”) on the KUKA flexFEL-
LOW in the correct position (left or right, depending on how the LBR is to be
installed).
Fig. 51: Installing the intermediate plate
1. Screw
2. Screw on the intermediate plate with 2 screws.
3. Insert the locating pins into the robot base.
4-30 V03-EN, 2016-08-31

Fig. 52: Installing the intermediate plate
1. (red) LBR iiwa 7 R800

2. (blue) LBR iiwa 14 R820
4. Place the LBR on the corresponding hole pattern.

5. Screw on the LBR as described in the robot assembly instructions.
6. Connect cables and pneumatic hoses, if applicable, to the robot.
7. Carefully screw on the protective cover, ensuring that the plastic is not dam-
aged.
V03-EN, 2016-08-31 4-31

flexFELLOW Operator control and operation
5 Operator control and operation

5.1 Switching on KUKA flexFELLOW
 Turn the main switch on the KUKA flexFELLOW to the position “1”.
After the main switch has been turned on, the system software starts automatical-
ly.
Fig. 53: KUKA flexFELLOW main switch
1. Main switch
5.2 Switching off KUKA flexFELLOW

1. Before turning off the main switch, make sure that the robot is at a standstill.
2. Turn the main switch on the KUKA flexFELLOW to the position “0”.
V03-EN, 2016-08-31 5-1

Operator control and operation flexFELLOW
5-2 V03-EN, 2016-08-31

flexFELLOW Maintenance and servicing
6 Maintenance and servicing

 To ensure troublefree operation, the product must be subjected to regular
maintenance. The maintenance intervals are determined by the operating
and ambient conditions as well as the design parameters.
 If ongoing maintenance reveals that the intervals are too long or too short,
they must be adapted to the existing operating requirements.
 Maintenance of the purchased components must be carried out in the first
instance in accordance with the operating instructions provided by the sup-
plier.
The service life and efficiency of the product depend to a considerable degree on
its maintenance and servicing. Preventive maintenance and servicing will sustain
the quality and operational safety of the product.
 Perform and check maintenance and servicing regularly in accordance with
the schedule.
6.1 Cleaning and preventive maintenance

 Before performing any cleaning and preventive maintenance work on the
product, have it de-energized by trained and authorized personnel.
 If necessary, clean dust and dirt from the product, using a non-linting cloth.
 The following points must be taken into consideration when using cleaning
agents and carrying out cleaning work:
■ Only use solvent-free, water-soluble cleaning agents.
■ Do not use flammable cleaning agents.
■ Do not use aggressive cleaning agents.
■ Do not use steam or refrigerants for cleaning.
■ Do not use high-pressure cleaners.
■ It must be ensured that no cleaning agent enters electrical or mechanical
system components.
■ Personnel protection measures must be taken.
 Before cleaning the product, cover or tape up all openings which – for safe-
ty and functional reasons – must be protected against ingress of water,
steam or cleaning agents.
 When carrying out maintenance, servicing or repair work, the lubricants and
cleaning agents specified by the relevant manufacturer must be used. The
inadmissible use of products other than those specified may result in guar-
antee and warranty claims being invalidated.
V03-EN, 2016-08-31 6-1

Maintenance and servicing flexFELLOW
6.2 Preventive maintenance

The KUKA flexFELLOW requires minimal maintenance.
The following checks should be performed at regular intervals:
 Perform a visual check for damage.
 Test the safety devices for proper operation and freedom from damage.
 Check the correct setting and electrical function of limit switches, sensors
and LEDs.
 Check moving parts and components for abnormal noises.
 Check the hydraulic lifting unit (optional equipment) for leaks (visual inspec-
tion).
6.2.1 Exchanging the air filter
For details of exchanging the air filter in the air conditioner and active fan, see
the Rittal operating instructions.
6.3 Corrective maintenance

6.3.1 Exchanging the rollers
Fig. 54: Exchanging the rollers
1. Roller
2. Screws and washers
Dismantling
1. Lift the product (for instance with a fork lift truck, see 4.3.2 Transport by fork
lift truck), so that the rollers on the underside are easily accessible.
6-2 V03-EN, 2016-08-31

2. Secure the KUKA flexFELLOW against sagging and falling.
WARNING Crushing hazard!

If the product is not properly secured it can topple over and crush personnel.
 Secure the product against slipping.
3. Undo four screws (2) on the roller (1).

4. Remove the roller (1) together with the screws and washers (2).
Installation
1. Attach a new roller (1) with four screws and washers (2).
2. Lower the product back on to the floor.
6.3.2 Exchanging the stack lights
Fig. 55: Installing the stack lights
1. Stack lights
2. Screws
Dismantling
1. Undo four screws (2) on the stack lights (1).
2. Remove the stack lights (1) and screws (2).
V03-EN, 2016-08-31 6-3

Installation
1. Place the new stack lights (1) on the function plate. When doing so, make
sure that the holes for the stack light screws line up with the tapped holes in
the function plate.
2. Attach the stack lights with four screws (2).
3. Connect the stack lights according to the following circuit diagram.
Fig. 56: Circuit diagram for the stack lights
6-4 V03-EN, 2016-08-31

6.3.3 Exchanging the covers on the function plate
Fig. 57: Covers on the function plate
1. Screws
2. Circular cover
3. Robot mounting plate
Dismantling
1. Undo the screws (1) on the circular cover (2) or the robot mounting plate (3).
2. Remove the screws (1) and the circular cover (2) or the robot mounting
plate (3).
Installation
1. Place a new circular cover (2) or new robot mounting plate (3) on the func-
tion plate. When doing so, make sure that the holes for the circular cover or
robot mounting plate screws line up with the tapped holes in the function
plate.
2. Tighten the screws (1) to secure the circular cover (2) or robot mounting
plate (3).
V03-EN, 2016-08-31 6-5

6.3.4 Exchanging the side panel
Fig. 58: Side panel
1. Fastener
2. Side panel
Dismantling
1. Undo the screws (1) on the side panel (2).
2. Remove the screws (1) and the side panel (2).
Installation
1. Place the new side panel (2) on the base unit. When doing so, make sure
that the holes for the side panel screws line up with the tapped holes in the
base unit.
2. Secure the side panel (2) with screws (1).
6-6 V03-EN, 2016-08-31

6.3.5 Exchanging the KUKA smartPAD holder
1
4
Fig. 59: KUKA smartPAD holder
1. Holder
2. Stack lights
3. Emergency Stop cover
4. Screws
5. Rail
Dismantling
NOTICE Damage to the KUKA smartPAD holder

When the screws on the KUKA smartPAD holder are released, the plate and
holder are liable to fall down.
 When undoing the screws, restrain the plate and holder.
1. Undo the screws (3) on the plate (4).

2. Remove the screws (3), plate (4) and holders (1).
Installation
1. Hold the plate (4) against the stack lights (2).
2. Place the holders (1) on the plate (4). When doing so, make sure that the
holes for the plate screws line up with the tapped holes in the holders.
3. Tighten the screws (3) to secure the holders (1) to the plate (4).
V03-EN, 2016-08-31 6-7

flexFELLOW Decommissioning
7 Decommissioning
The product must be decommissioned, stored and disposed of in accordance

with the applicable national laws, regulations and standards.
7.1 Temporary decommissioning

1. Move the installed robot into its transport position (see 4.3 Transportation).
2. Switch off the KUKA flexFELLOW (see 0 Switching off the KUKA flexFEL-
LOW).
3. Unplug the interface connector.
4. Transport the KUKA flexFELLOW away (see 4.3 Transportation).
7.2 Corrosion protection and storage

1. If the product is to be placed in storage for an extended period, the following
points must be observed:
■ Keep the storage location generally dry and free from dust.
■ Avoid temperature fluctuations.
■ Avoid wind and drafts.
■ Avoid condensation.
■ Select coverings that cannot become detached and are capable of with-
standing environmental influences.
■ Avoid exposure to direct sunlight during storage.
■ Observe and comply with temperature ranges for storage.
■ Select the storage location so that the covers cannot be damaged.
2. Clean all components. No fouling may be left on the components.
3. Subject all components to a visual inspection.
4. Remove foreign bodies.
5. Remove any corrosion expertly.
6. Fit all covers and make sure that they are impermeable.
7. Seal off electrical connections with suitable covers.
8. Cover the product with weatherproof and tear-resistant plastic sheeting, and
seal it against dust.
9. Provide an additional desiccant inside the sheeting if necessary.
V03-EN, 2016-08-31 7-1

Decommissioning flexFELLOW
7.3 Disposal
When the product reaches the end of its useful life, it can be dismantled, and the
materials can be disposed of properly by type.
The product contains electronic components, copper parts, refrigerant and hy-
draulic fluid. These components must be disposed of in a correct manner so as
not to pose an environmental hazard.
 Liquids must be poured into a suitable container before disposal.
7-2 V03-EN, 2016-08-31

flexFELLOW Service and spare parts
8 Service and spare parts

8.1 Service
Service packages such as teleservice, maintenance and inspections guarantee
the high availability of your KUKA system in the long term.
The KUKA Systems GmbH Training Center offers you customized training pack-
ages covering every aspect of the systems, machines, components and process-
es, ensuring that you derive maximum benefit from your investment.
KUKA Systems GmbH offers a three-year maintenance package for the KUKA
flexFELLOW. This consists of the following services:
■ Electrical testing
■ Replacement of the castors
■ Replacement of the filter mats
■ Replacement of the gas spring as a counterbalancing system for the height-
adjustable handle
■ Replacement of the LED lamp
■ Renewal of the advertising and warning signs
■ Optional: Replacement of the Harting connectors
8.2 Spare parts

Spare parts from KUKA Systems are matched to your KUKA flexFELLOW. Only
original spare parts are offered.
If, in the event of a fault, or when stocking up on spare parts, you are not sure
which parts you require, our team will be happy to assist you.
Designation Quantity Illustration

Castor assy 4
Magnet assy incl. connector and 1

fastening (only to be exchanged
by qualified KUKA personnel)
Filter mats for fan 1 –
V03-EN, 2016-08-31 8-1

Service and spare parts flexFELLOW

Stack lights assy incl. mounting 1
tube and connector (stack lights)
KUKA smartPAD holder 1
Side panel 1
Covers assy for work plate

(ground):
■ Circular cover 4
see Section 6.3.3
■ “Robot mounting plate” 1
see Section 4.9.4
Crank for raising the trolley 1
Mating connector for -X0 1 –
8-2 V03-EN, 2016-08-31

flexFELLOW Service and spare parts

Mechanical locking system 1
Grid plate 1
V03-EN, 2016-08-31 8-3

Service and spare parts flexFELLOW
8.3 Contact
Address KUKA Systems GmbH

Blücherstrasse 144
86165 Augsburg, Germany
Germany
Internet www.KUKA.com
e-mail info@KUKA.com
KUKA Service Tel: +49-(0)821 / 797-2002
Fax: +49-(0)821 / 797-1543
service@KUKA.de
KUKA Spare Parts Tel: +49-(0)821 / 797-1001
Fax: +49-(0)821 / 797-1543
service@KUKA.de
8-4 V03-EN, 2016-08-31

flexFELLOW Declaration of Conformity
9 Declaration of Conformity
V03-EN, 2016-08-31 9-1

Declaration of Conformity flexFELLOW
9-2 V03-EN, 2016-08-31

flexFELLOW Declaration of Conformity
V03-EN, 2016-08-31 9-3

flexFELLOW Index
10 Index
A Hazard symbols 3
Assembly 4-1 I
C Information about the operating instructions
Climatic conditions 2-8 1
Components Installation 4-1, 4-9
optional 3-15 with locking device 4-9
Connecting the KUKA smartPAD 4-29 without locking device 4-9
Connection data 2-7 Installation location 4-2
Connector X0 3-24 Installing robot components 4-26
Contact 8-5 Installing the Emergency Stop button 4-18
Corrective maintenance Installing the laser scanners 4-21
Covers 6-5 Installing the robot 4-30
KUKA smartPAD holder 6-7 Installing the stack lights 4-7
Rollers 6-2 Intended use 1-6
Side panel 6-6 L
Stack lights 6-3 Laser scanner 3-21
D Legal conditions 1
Danger M
Electrical energy and electrical Maintenance 6-1
equipment 1-5 Misuse 1-6
Pneumatic equipment 1-5 N
Decommissioning
Temporary 7-1 Notes and symbols 3
Decommissioning 7-1 O
Disclaimer 1-1 Operating data 2-7
Disposal 7-2 Operation
Docking Electrical installation 4-15
Magnetic docking 4-16 Power supply 4-15
Mechanical docking 4-17 Optional components 3-15
Documentation for the KUKA flexFELLOW P
1
Personnel 1-3
E
Pneumatic components 3-22
Electromagnetic compatibility 2-8 Power supply 4-15
Emergency Stop pushbutton 3-20 Preventive maintenance 6-1, 6-2
Energy and power supply 3-23 Product description 3-1
Engage interlock 4-14 Base unit 3-6
Equipotential bonding 4-15 Connection interface X0 3-13
Exchanging the air filter 6-2 Cooling unit with active fan 3-13
F Cooling unit with air conditioner 3-12
Flange plate 3-16 Fixed handle 3-8
H Function plate 3-5
Height-adjustable handle unit 3-9
Hazard areas 1-3
Locking device 3-10
V03-EN, 2016-08-31 1
Index flexFELLOW
Magnetic locking system 3-15, 3-19 Service socket X0 3-23

Pneumatic unit 3-8 Space requirements 2-7
Sensor for the lower handle position 3- Spare parts 8-1
10 Start-up
Stack lights 3-11 Switching off KUKA flexFELLOW 5-1
Transport unit with raise/lower facility 3- Switching on KUKA flexFELLOW 5-1
11 Storage 7-1
Transport unit with raise/lower facility Switching off KUKA flexFELLOW 5-1
(ESD) 3-11 Switching on KUKA flexFELLOW 5-1
Transport unit without raise/lower facility
T
3-11
Transport unit without raise/lower facility Target group 1
(ESD) 3-11 Technical data 2-7
Variants 3-5 Protection rating 2-7
View of the KUKA flexFELLOW 3-2 Space requirements 2-7
Protection rating 2-7 Terms 4
R Text conventions 1
Transport
Rating plate 3-4
Fork lift truck 4-3
Restrictions on use 1-6
Manual 4-4
S
Transporting the packaged product 4-1
Safety U
Maintenance and servicing 1-5
Unpacking the packaged product 4-1
Safety equipment and safeguards 1-2
V
Safety information 1-1
Safety instructions Variants 3-5
Commissioning 1-5 W
Safety regulations 1-4 Working areas 1-3
Service 8-1
2 V03-EN, 2016-08-31

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KUKA flexFELLOW

Issue: V03-EN, 2016-08-31

Manufacturer and distributor

© KUKA Systems GmbH 2016

V03-EN, 2016-08-31 III

3.5.3 Pneumatic unit ..................................................................................................3-8

4.7.2 Mechanical docking (optional) ........................................................................ 4-17

Information about the operating instructions

Documentation for the KUKA flexFELLOW

This documentation is applicable to all components of the KUKA flexFELLOW.

Means of represen- Description

Depiction of notes and symbols

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

Term Definition Explanation

External cross-references and links

V03-EN, 2016-08-31 1-1

1.2 Safety equipment and safeguards

1.2.2 Safety measures

1-2 V03-EN, 2016-08-31

1.2.3 Working areas and hazard areas

V03-EN, 2016-08-31 1-3

1.4 Safety regulations

 Avoid any operational mode that might be prejudicial to safety.

1-4 V03-EN, 2016-08-31

1.5 Safety instructions governing specific operating conditions

1.5.2 Maintenance and servicing

1.6 Warning of special hazards

1.6.2 Pneumatic equipment

1.7 Restrictions on use

V03-EN, 2016-08-31 1-5

1.7.2 Improper use

1-6 V03-EN, 2016-08-31

2.2 Protection rating

2.3 Connection and operating data

V03-EN, 2016-08-31 2-7

A residual current circuit-breaker must be connected externally to the power

2.3.1 Electromagnetic compatibility (EMC)

The KUKA flexFELLOW is intended for use in an industrial environment with a

2.4 Climatic conditions

Ambient temperature during operation with +5 °C to 40 °C

2-8 V03-EN, 2016-08-31

V03-EN, 2016-08-31 3-1

3.2 View of the KUKA flexFELLOW

Function plate with

Fig. 1: General setup of the KUKA flexFELLOW

3-2 V03-EN, 2016-08-31

3.3 Scope of supply

V03-EN, 2016-08-31 3-3

3.4 Rating plate

Fig. 2: KUKA flexFELLOW rating plate acc. to Low-Voltage Directive and

3-4 V03-EN, 2016-08-31

3.5.1 Function plate

Fig. 3: View of the KUKA flexFELLOW function plate

V03-EN, 2016-08-31 3-5

3.5.2 Base unit

Fig. 4: View of the door side of the KUKA flexFELLOW

3-6 V03-EN, 2016-08-31

V03-EN, 2016-08-31 3-7

3.5.3 Pneumatic unit

Fig. 5: KUKA flexFELLOW pneumatic unit

The KUKA flexFELLOW should be supplied with compressed air to ISO8573-1,

3.5.4 Fixed handle unit

3-8 V03-EN, 2016-08-31