KUKA LBR iisy 3 R760 Collaborative Robot Debugging Guide

KUKA LBR iisy 3 R760 Collaborative Robot Debugging Guide

Introduction: The Engineering Value of the New Generation Collaborative Robots

KUKA LBR iisy 3 R760 is a new generation of lightweight industrial robot designed for human-machine collaboration scenarios. It has a rated load of 3kg, a maximum working radius of 760mm, and a body weight of only about 22.8kg. The robot adopts a 6-axis articulated design, with all drive units and current carrying cables built into the body. The protection level is IP30, and it supports installation on the ground, walls, ceilings, and at any angle (± 180 ° tilt angle).

Unlike traditional industrial robots, LBR iisy integrates sensors on each axis - axis range sensors ensure compliant motion range, torque sensors monitor load limits, and temperature sensors protect electronic devices. The Commander interface is located on the wrist and integrates a hand guided handle, jog dial, enable switch, and back button, supporting direct drag teaching. This robot is compatible with KR C5 micro controller and runs KUKA iiQKA.OS system software. This article is based on the official assembly manual of KUKA, systematically sorting out the technical points of the entire process from mechanical installation, electrical connection, toothed belt maintenance to shell replacement, helping engineers quickly master the deployment and maintenance of the robot.

Overview and Technical Parameters of Product Series

2.1 Basic Parameters

Parameter specifications

Number of axes 6 (all controlled)

Work envelope volume 0.88 m ³

Pose repeatability accuracy ± 0.1 mm

The weight of the body is about 22.8 kg

Rated/maximum load 3 kg/3.34 kg

Maximum working radius 760 mm (including output flange)

Protection level IP30 (whole machine and wrist)

Noise level<75 dB (A)

Controller KR C5 micro

Installation location: Ground, wall, ceiling, any angle

Base hole type C184 (installation circle diameter 210mm)

2.2 Axis motion data

Motion range: A1 ± 185 °, A2-230 °/50 °, A3 ± 150 °, A4 ± 175 °, A5 ± 110 °, A6 ± 220 °. The speed parameters are very impressive: A1~A3 are all 200 °/s, A4~A5 reach 300 °/s, and A6 is as high as 400 °/s, making the robot highly responsive in light load assembly and inspection scenarios.

2.3 Environment and Installation Conditions

The working temperature is 5-45 ℃, the storage/transportation temperature is -25~70 ℃, and the operating humidity is 20%~80%. The installation base is of C184 hole type (bolt circle diameter 184mm), and the base occupies an area of approximately 210mm circular. The robot supports installation at any angle, but when not installed on the ground, the tilt angle parameters (A, B, C directions) must be correctly configured through the system software, otherwise it may cause unforeseeable motion or overload. In addition, special attention should be paid to the possibility of losing control of internal electrical connections when operating in conductive dirt or condensation environments. Therefore, the installation site must prevent conductive contamination and condensation.

Mechanical installation and rack installation

3.1 Rack Installation Components

LBR iisy adopts the machine frame mounting method to fix the robot on the steel frame, elevated seat or KUKA linear guide prepared by the customer. The installation kit (article number 0000-204-931) includes:

4 M8 × 30-8.8-A2K hexagon socket screws (with disc spring washers)

1 cylindrical positioning pin and 1 flat positioning pin (ensuring precise alignment)

8 M24 × 65-8.8-A2K hex bolts (used for fixing the base)

3.2 Installation steps

Clean the installation surface: Remove grease, rust, or adhesives.

Check hole position: Confirm that the hole position on the installation surface matches the base hole type.

Installation positioning pin: Rotate the cylindrical and flat positioning pins into the installation surface and check the firmness.

Lifting robot: Use lifting equipment to move the robot to the installation position and maintain an absolute vertical descent to prevent damage to the positioning pin.

Placed in place: The robot base aligns with the positioning pin and slowly descends until it fully fits.

Insert screws: Install 4 M8 × 30-8.8-A2K hex socket screws with disc spring washers.

Diagonal incremental tightening: Use a torque wrench to gradually increase the torque to the specified level (M8 8.8, approximately 23 Nm).

3.3 Foundation load verification

The force and torque generated by the robot's motion will be transmitted to the foundation. Taking ground installation as an example:

Normal vertical force F (v normal)=280N, maximum F (v max)=530N

Horizontal force F (h normal)=120N, maximum F (h max)=530N

Tilt moment M (k normal)=100Nm, maximum M (k max)=380Nm

The installation foundation must be able to permanently withstand these loads. Improper foundation design may lead to structural failure. 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 controller through two sets of main cables:

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.

Control measurement: Start the robot and move A5 back and forth about 20 ° twice. Move the robot to the measurement position (with tools: arm level and A4 within ± 90 °; Can be placed anywhere without tools). Measure the frequency at the center of the upper and lower sides of the toothed belt, calculate the average value, and compare it with 155 ± 5 Hz. If it does not meet the standard, repeat the adjustment.

Install cover plate: Position the cover plate and secure it with one M3 × 6-10.9 TORX screw.

Conclusion: Perform zero calibration for A5 and A6 (see system software documentation), and conduct a trial run in T1 mode to check for abnormalities.

Shell replacement

LBR iisy 3 R760 adopts a plastic shell, which can be replaced separately or as a set (spare SPP shell set 0000-332-499). The installation methods of different parts of the shell are different:

Rotating column housing: 1 external M3 × 6-8.8-A2K TORX screw+3 internal PT K30 × 10-10.9-A3K TORX screws

Connecting arm shell: external 2 M3 × 6-10.9-A2K TORX screws+internal 6 PT K30 × 10-10.9-A3K TORX screws

A3 axis arm shell: external 1 M3 × 6-10.9-A2K TORX screw+internal 3 PT K30 × 10-10.9-A3K TORX screws

Main body shell: including toothed belt cover plate, the cover plate needs to be removed before disassembly

Rotating shell shell: 1 M3 × 6-10.9-A2K TORX screw on the outside and 3 PT K30 × 10-10.9-A3K TORX screws on the inside

When disassembling, use a flat head screwdriver to carefully pry open the buckle connection between the upper and lower shells. Pay attention to the "click" sound when the buckle is in place during installation. All screws must be tightened to the specified torque.

Option Description

9.1 Claw and finger set (optional)

Servo electric drive 2-finger parallel gripper (Co Act ESG-C K060, approximately 0.5kg), with safety limits on the gripping force itself. Requires 24V power supply and 2 inputs/2 outputs (provided through controller XG12/XD12). When replacing, first remove the plug-in connector module on the Commander, and then remove the 4 M3 × 8-8.8 hex screws.

9.2 Output flange (optional)

When the robot is delivered without grippers, it comes standard with an ISO 9409-1-50-7-M6 output flange (approximately 0.11kg), allowing users to install custom tools. The flange is fixed with 8 M3 × 10-8.8-A2K hexagon socket screws and equipped with 2 3 × 10-A-St positioning pins. Removing the output flange can improve the distance between the payload and the center of gravity of the load.

9.3 Connector adapter X94/X96 (optional)

Used for contacting external interface A6, including Gigabit, I/O, and power connections. The cable length is 0.5m and the maximum number of insertions and removals is 50 times. During installation, the A6 cover plate needs to be removed first, and then the X94/X96 should be inserted into the adapter and fixed with 3 M3 × 8-8.8-A2K hex socket screws.

Transportation and discontinuation

10.1 Transportation posture

Before transportation, the robot must be moved to the designated transportation position: A1=0 °, A2=-115 °, A3=140 °, A4=0 °, A5=50 °, A6=0 °. The external dimensions of the transportation packaging are 800 × 600 × 620mm.

10.2 Disabling Storage

When not in use, the robot needs to be moved to the transport position, all cables disconnected, 4 M8 × 30-8.8-A2K hex bolts removed, and vertically lifted off the installation surface. The storage location should meet the following requirements: dry and dust-free, avoid temperature fluctuations, prevent condensation, and be free from direct sunlight. Wrap with plastic film and seal the base to prevent dust.