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)

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

Fix with 8 M4 × 12-A4-80 hex screws, torque 2.8Nm

Special precautions for CR cleanroom models

The CR model has been optimized for cleanroom applications based on the standard model:

Cleanroom Class: ISO 14644-1 Class 3 (at 40% magnification)

Sealing treatment: the foam sealing gasket inside the wrist main body cover plate needs to be lightly coated with Kl ü bersynth BEM 34-32 grease to improve the particle sealing

Other mechanical parameters are completely consistent with the standard model

When used in a clean room environment, special attention should be paid to the cleaning procedures to avoid introducing particle contamination.

Transportation and discontinuation

10.1 Transportation posture

Before transportation, the robot must be moved to the designated position: A1=0 °, A2=-75 °, A3=-120 °, A4=0 °, A5=105 °, A6=0 °.

10.2 Transportation mode

It can be transported using a crane and sling (see the schematic diagram in the manual), with the sling wrapped around the A3 gearbox unit. Due to the inclined posture of the robot, it is necessary to avoid tilting the positioning pin under force during lifting and lowering.

10.3 Disabling Storage

When not in use, the robot needs to be moved to the transport position, all cables disconnected, 4 M10 × 35-8.8-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. It should be wrapped in plastic film and sealed at the base to prevent dust.