Installation and Maintenance Guide for KUKA LBR iisy Series Collaborative Robots

Installation and Maintenance Guide for KUKA LBR iisy Series Collaborative Robots

Introduction: Overview of LBR iisy Product Family

The KUKA LBR iisy series is a new generation of lightweight robot product line for human-machine collaboration and Industry 4.0 scenarios, covering six models: LBR iisy 6 R1300、LBR iisy 8 R930、LBR iisy 11 R1300、LBR iisy 11 R1300 CR、LBR iisy 15 R930  And LBR iisy 15 R930 CR. The CR suffix represents the cleanroom variant, which complies with ISO 14644-1 Class 3 standard (at 40% magnification) and is suitable for environments with strict control of particulate matter, such as semiconductor, pharmaceutical, and precision electronic manufacturing.

This series of robots adopts a 6-axis articulated design, with all drive units and current carrying cables built into the body. The protection level is IP54 (for the whole machine and wrist), and it supports installation on the ground, walls, ceilings, and at any angle (± 180 ° tilt angle). The Commander interface is located on the wrist and integrates a hand guided handle, enable switch, rotary dial, and back button, supporting direct drag teaching. This article is based on the official assembly manual of KUKA, systematically summarizing the technical points of the entire process from mechanical installation, electrical connection, toothed belt maintenance to CR model special requirements.

Product model comparison and key parameters

2.1 Comparison of Technical Parameters of Various Models

parameter  LBR iisy 6 R1300 LBR iisy 8 R930 LBR iisy 11 R1300 LBR iisy 11 R1300 CR LBR iisy 15 R930 LBR iisy 15 R930 CR

Rated/maximum load  6kg / 6.9kg 8kg / 9.6kg 11kg / 11.72kg 11kg / 11.72kg 15kg / 16.41kg 15kg / 16.41kg

Maximum working radius 1300mm 930mm 1300mm 930mm 930mm

Work envelope volume 5.72m ³ 1.73m ³ 5.72m ³ 5.72m ³ 1.73m ³ 1.73m ³

The weight of the body is about 46.3kg, about 43.2kg, about 46.3kg, about 46.3kg, about 43.2kg, about 43.2kg

Positioning repeatability accuracy ± 0.05mm ± 0.05mm ± 0.05mm ± 0.05mm ± 0.05mm ± 0.05mm ± 0.05mm

Cleanroom Class - Class 3- Class 3

Base hole type C246 C246 C246 C246 C246 C246 C246

2.2 Axis motion data

All models have the same range of motion: A1 ± 185 °, A2-230 °/50 °, A3 ± 150 °, A4 ± 180 °, A5 ± 110 °, A6 ± 220 °. The speed parameters vary slightly depending on the model: A1~A3 are all 200 °/s, A4 230 °/s, A5 260 °/s, A6 is 380 °/s in the R930 model, and 430 °/s in the R1300 model.

The CR cleanroom model meets ISO Class 3 standards at 40% magnification and is suitable for applications with high cleanliness requirements.

Mechanical installation method

The LBR iisy series supports two main installation methods, depending on the site conditions.

3.1 Installation Base (optional, ground mounted)

The installation base (article number 0000-311-958, approximately 16.5kg) is used to directly fix the robot on a concrete foundation. The base includes:

Bottom plate

Chemical anchor bolts (4 pieces)

Tightening components

Installation points:

The concrete foundation must meet the strength grade requirements of C20/25 (EN 206)

There shall be no insulation layer or leveling layer between the bottom plate and the concrete foundation

When using chemical anchor bolts, the resin hose and anchor bolts must come from the same manufacturer

Diamond tools or coring drills are prohibited for drilling, and drilling tools provided by anchor bolt manufacturers are preferred

Anchor holes must be strictly constructed according to the manufacturer's instructions

Tightening torque of anchor bolt: chemical anchor bolt nut 80.0 Nm, tightening bolt 45.0 Nm.

3.2 Rack installation (optional, wall/ceiling)

Rack installation (article number 0000-204-468, approximately 0.161kg) is used to secure the robot to the steel structure, height stand, or KUKA linear guide prepared by the customer. include:

Positioning pin (1 cylindrical and 1 flat)

Hexagonal bolt with disc spring washer (4 pieces)

Key requirements:

The base material must ensure shear strength (such as S355J2G3)

Fix with 8 M10 × 35-8.8-A2K hex bolts (disc spring washers)

Tightening torque: M10 8.8 grade, approximately 45 Nm

It must be installed in a stress free state to avoid deformation of the base

Electrical connections and interface definitions

4.1 Overview of Connecting Cables (KR C5 micro)

The robot is connected to the controller through the following cables:

Motor cable: Han Jellock ®  30, connect controller XD20.1/XD20.2 → robot X30

Data cable: Han ®  Q12， Connect controller XF21 → robot X31

Grounding conductor: 4mm ² M4 ring terminal

Standard cable lengths of 1m, 4m, 7m, 15m, and 25m are optional, with a maximum length of 25m and allowing for one extension. The minimum bending radius for fixed installation is 5 times the cable diameter.

4.2 Interface A1 (rear of base)

Motor cable X30: connected to controller XD30, transmitting A1-A3 and A4-A6 motor power (including brake)

Data cable X31: connected to controller XF31

Energy supply system interface: XF74 (Gigabit, M12 X encoding) and XG76 (I/O, M12 8-pin A encoding)

4.3 Energy supply system interface A6 (under wrist Commander)

XF94: Gigabit interface (CAT5e, 8-pin)

XG96: Power supply, digital input/output (8-pin)