KUKA LBR iico Robot Installation and Debugging Technical Guide

Horizontal force F (h normal)=278N, maximum F (h max)=624N

Tilt moment M (k normal)=308Nm, maximum M (k max)=684Nm

The installation foundation must be able to permanently withstand these loads. Improper foundation design may lead to structural failure and cause serious safety accidents. The specified installation equipment should be used in the project, and the load should be calculated according to each specific working condition.

Electrical connections and interface definitions

4.1 Overview of Connecting Cables

The robot is connected to the KR C5 micro-2 controller through two sets of cables:

Motor cable: Connect controller XD20.1/XD20.2 → robot X30, transmit motor power and brake power

Data cable: Connect controller XF21 → robot X31, transmit position feedback, torque signals, and temperature data

Grounding conductor: M4 ring terminal connected to the robot base and controller grounding terminal (optional, but recommended for mandatory installation)

The standard length of the cable is 4m, 7m, 15m, with a maximum length of 15m, and extension is not allowed. When fixed installation, the bending radius of motor cables should not be less than 120mm, and that of data cables should not be less than 60mm. The cables must be laid separately in metal cable trays to avoid EMC interference.

4.2 Wrist external interfaces X1 and X2

The robot wrist Commander is equipped with two M8 interfaces:

X1 (8-pin, A code): Rated current 1A, voltage 24V DC ± 10%, providing two digital inputs, two digital outputs, RS485 communication (A/B), requiring overload and short circuit protection from the user end.

X2 (6-pin, A-code): specifically designed for MEMD adapter cables, providing 24V power supply and RS485 communication (TX/RX).

It is recommended to use the "effective high-level input" method for the input wiring of X1, and the "effective low-level output" method for the output. Be sure to strictly follow the typical wiring diagram in the instruction manual, otherwise it may cause short circuit damage to the FIOB board.

4.3 Grounding and equipotential connection

In addition to the shielding layer inside the cable, an additional grounding conductor (cross-sectional area ≥ 4mm ²) must be installed between the robot and the control cabinet to establish a low impedance connection. The robot base is equipped with M4 threaded holes for connecting grounding terminals, with a tightening torque of 2.8 Nm. The equipotential connection must comply with the requirements of VDE 0100 and EN 60204-1.

Safety regulations and collaborative operations

The LBR iico design complies with ISO 10218-1 Class II (collaborative robots) requirements, but safety integration remains the responsibility of the system integrator.

5.1 Basic Safety Principles

Robots must be used for their intended purpose in a technically sound state, and any functional malfunctions must be immediately resolved.

Unauthorized modifications to robots are prohibited, otherwise the warranty will be invalidated.

The integrator is responsible for risk assessment, implementation of safety functions, CE compliance declaration, and preparation of system operation manuals.

If the safety function or protective device is removed or disabled, it is strictly prohibited to operate the robot.

5.2 Personnel Qualifications

Operators must undergo professional training and understand relevant standards and documents.

In emergency situations, non powered mobile robots may be required, and personnel must have received relevant training.

All work must be performed by qualified personnel, and unqualified operations may result in serious injuries.

5.3 Hazardous areas and protective distances

The hazardous area consists of a workspace and a stopping distance, and must be protected by physical protective devices such as safety fences.

If there is no physical protection, the requirements for collaborative operation in EN ISO 10218 must be met.

In manual mode (T1), the speed limit is ≤ 250mm/s, but during manual guidance operation, the speed is limited by safety monitoring rather than reduced.

It is recommended to maintain a safe distance of at least 50cm between the operator and the robot (including tools), which should be determined based on risk assessment.

5.4 Start stop safety

New or modified programs must be tested first in T1 mode, even if only global point data is modified.

Before debugging, it is necessary to change the default password of the system software to prevent unauthorized access.

Personnel with active implants such as pacemakers must maintain a distance of at least 300mm from the motor and brake - even if the motor is not powered, there is still an electromagnetic field present.

Stop distance and time

The stopping distance is a key input in the design of safety fences, consisting of reaction distance and braking distance. The following data is from the measurement method in Appendix B of ISO 10218-1, based on uniaxial motion under rated load, 100% program magnification, and 100% extension conditions.

6.1 STOP 0 (Emergency Stop)

STOP 0 is a stopping method that immediately cuts off the driving power and applies the brake. It has a high system load and should be avoided as much as possible