KUKA LBR iisy 3 R760 Collaborative Robot Debugging Guide

Motor cable: Controller XD20.1/XD20.2 → Robot XM1/XM2-6 (two connectors corresponding to A1-A3 and A4-A6, including brake power supply)

Data cable: Controller XF21 → Robot X15/X18

Grounding conductor: M4 ring terminal connected to the robot base and controller grounding terminal (standard cable length 7m, maximum 7m, no extension allowed)

When fixed installation, the bending radius of motor cables should not be less than 150mm, 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 Interface A1

Located at the rear of the base, it includes:

X74 (Gigabit cable, M12): Gigabit Ethernet communication

X76 (I/O cable, M12， 8-pin, A code): rated current 2A, voltage 24V, including digital input/output and power supply

X70 (power supply, M8， 4-pin, A code): Internal interface power supply

Data cable (X15/X18) and motor cable (XM1/XM2-6) connectors

The entire energy supply system of X76 and X70 must be protected against overload and short circuit by the user upstream of the connector.

4.3 External interface A6 (optional)

Located on Commander, connector adapter X94/X96 (optional) is required for contact. This interface includes:

X94 (Gigabit interface, CAT5e， 8 needles)

X96 (power supply, digital input/output, 8-pin)

Important: Only use KUKA connector adapters to contact external interface A6, otherwise serious injury or property damage may occur. Pre allocation can be modified according to specific customer applications.

Example configuration (with SCHUNK gripper):

Power supply: 24V DC (-15%/+20%), 2A

Digital output: 24V switch, maximum 0.5A/output

Digital input: reference point 0V

Maximum cable length: 0.5m

Safety regulations and key points for collaborative operations

5.1 Collaborative Operation Requirements

LBR iisy design complies with ISO 10218-1 Class II requirements. If there is no physical protective device, it must meet the requirements for collaborative operation. 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.

5.2 Hazardous Areas and Protection

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

When there is no physical protection, collaborative operation requirements must be met, and there must be no cutting or squeezing hazards in the loading and transfer areas.

5.3 Start Stop and Mode

New or modified programs must be tested first in T1 mode.

When guiding in T1 mode, the speed is limited by safety monitoring (non speed reduction).

Before debugging, the default password for the system software must be changed.

Stop distance and time

The stopping distance is a key input for safety fence design, based on single axis motion measurement under rated load, 100% program magnification, and 100% extension conditions.

6.1 STOP 0 (Emergency Stop)

A1 stop angle 16.01 °, A2 18.15 °, A3 5.77 °

A1 stop time 0.17s, A2 0.17s, A3 0.12s

6.2 STOP 1 (Controllable Stop)

Detailed stopping distance and stopping time curves of A1~A3 under different load masses (0kg, 0.25kg, 0.3kg, 0.35kg) and program magnifications (33%, 66%, 100%) are provided. In practical applications, multi axis composite motion can cause longer stopping distances, and it is necessary to conduct actual testing and verification.

Maintenance points and replacement of toothed belts

7.1 Maintenance cycle

Periodic tasks

Check the tightening torque of fastening screws/nuts 100 hours (once only) after startup/re debugging

Replace A5 toothed belt every 5000 hours or at the latest 1 year

It is recommended to conduct a comprehensive inspection of the robot every 7 years or when there is a change in usage (contact KUKA Service)

7.2 Detailed process for replacing A5 toothed belt

The A5 shaft of LBR iisy 3 R760 is driven by a toothed belt and requires regular replacement and adjustment of tension using a frequency meter.

Required equipment:

Hexagonal wrench set

TORX wrench set

TSM alpha frequency meter (article number 20071-053-386)

Spare parts: SPP belt assembly IW 3 R760 (0000-332-496)

Replacement steps:

Fixed A5 axis: Remove or fix the tool, or move the arm to a horizontal position with A4 at ± 90 °, or move the arm to a vertical position with A5 at 0 ° to prevent accidental rotation during replacement.

Remove the toothed belt cover plate: unscrew one M3 × 6-10.9 TORX screw and remove the cover plate.

Remove the old toothed belt: Loosen 2 M3 × 10-8.8 hex screws and 1 M4 × 25-8.8 hex adjusting screw, and remove the old toothed belt from the pulley.

Install new toothed belt: Ensure that the new toothed belt meshes correctly with the belt pinion.

Initial tension measurement: Gently tighten the adjusting screw to the pre tightened state, and lightly tighten 2 M3 × 10-8.8 hex screws to fix the pulley. Using a frequency meter, place the sensor on the central side of the toothed belt (maintaining a distance of 2-3mm), and rotate the belt to read the frequency. Set value: 155 ± 5 Hz. If it does not meet the standard, loosen the fixing screw, adjust the tension with the adjusting screw, and then re measure.