Installation and Maintenance Guide for KUKA LBR iisy Series Collaborative Robots

Contact must be made using connector adapter A6 (optional), only KUKA original adapters are allowed.

Safety regulations and collaborative operations

5.1 Collaborative Operation Requirements

LBR iisy design complies with ISO 10218-1 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, which must be protected by physical protective devices

There shall be no cutting or squeezing hazards in the loading and transfer area

New or modified programs must be tested first in T1 mode

5.3 Implant Safety

Both the motor and brake generate electromagnetic fields when powered on or off, and personnel equipped with active implants such as pacemakers must maintain a distance of at least 300mm from the motor/brake.

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 R1300 Model Group (LBR iisy 6 R1300/11 R1300/11 R1300 CR)

STOP 0 (emergency stop):

A1 stop angle 11.56 °, A2 9.60 °, A3 6.44 °

Stop time: A1 0.38s, A2 0.15s, A3 0.10s

STOP 1 (Controllable Stop): Provides detailed curves of A1~A3 under different load masses (0kg, 0.25kg, 0.3kg, 0.35kg) and program magnifications (33%, 66%, 100%).

6.2 R930 Model Group (LBR iisy 8 R930/15 R930/15 R930 CR)

STOP 0 (emergency stop):

A1 stopping angle 9.98 °, A2 8.67 °, A3 6.96 °

Stop time: A1 0.10s, A2 0.11s, A3 0.09s

Suggestion: Conduct a brake test at least once a year. STOP 0 imposes a significant load on the system and should be avoided as much as possible.

Maintenance points

7.1 Maintenance cycle

Periodic tasks

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

Check the installation base clamping bolt torque every year (if used)

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 A5 toothed belt replacement (R1300 model group)

Required equipment:

Hexagonal wrench set, TORX wrench set (TX5-TX15)

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

Spare parts: toothed belt 6 HTD-5M/755 HP (0000-391-214)

Lubricating grease: Kl ü bersynth BEM 34-32 (approximately 2g)

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 °.

Remove the wrist body cover plate: unscrew 11 M3 × 8-10.9 TORX screws and remove the cover plate.

Remove the old toothed belt: Loosen 3 M4 × 14-8.8 hex screws and 1 M4 × 16-8.8 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 3 M4 × 14 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 and adjust it with the adjusting screw before re measuring.

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 the set value.

Install the cover plate: check the foam gasket inside the cover plate. For CR model, apply Kl ü bersynth BEM 34-32 grease on the gasket. Fix with 11 M3 × 8-10.9 TORX screws (torque 0.5Nm).

7.3 A5 toothed belt replacement (R930 model group)

Similar to the R1300 model group, the difference lies in:

The cover plate only has 7 M3 × 8-10.9 TORX screws

The spare parts for the toothed belt are 6 HTD-5M/425 HP (0000-391-213)

Tension setting value: 112 ± 5 Hz

7.4 Robot Cleaning

Only use solvent based, water-soluble, non flammable, and non corrosive cleaning agents

Prohibit the use of high-pressure cleaning machines

Compressed air should not be used for cleaning bearings and sealing points

Ensure that cleaning agents do not enter electrical or mechanical system components

ISO flange replacement

8.1 Disassembly

Unscrew 8 M4 × 12-A4-80 hexagon socket screws (with USIT sealing ring)

Separate the adhesive between Commander and ISO flange

Remove the ISO flange (including O-ring)

Take out one 3 × 14-A-St positioning pin

8.2 Installation

Insert one 3 × 10-A-St positioning pin into the hole on the back of the ISO flange

Install the new O-ring into the ISO flange groove

Apply Loctite 510 surface sealant on the O-ring

Position the ISO flange to the Commander and align the locating pin