KUKA LBR iiwa CR Operations and Troubleshooting

Maintenance plan and cleaning requirements

The maintenance interval is based on the operating conditions in the technical data. If the operating conditions deviate, KUKA should be consulted. Typical maintenance table:

Interval activity

Check the bolts after 100 hours of operation. 7 R800 torque is about 23 Nm; 14 R820 torque is about 45 Nm

Tighten all at once after startup/installation according to the above instructions

1 year visual inspection and check for fan operating noise

Replace the fan within 3 years (25 ℃ environment)

Fans can only be replaced by authorized maintenance personnel after consultation with KUKA customer support. When cleaning robots, only cleanroom approved cleaning agents and tools, such as cleanroom cloths, can be used. Do not use corrosive cleaning agents, steam, refrigerants, or high-pressure cleaning machines. Cleaning agents must be prevented from entering electrical or mechanical components. After cleaning, thoroughly remove the cleaning agent, clean the workspace, dispose of the cleaning agent properly, restore safety equipment and check its function, replace damaged or unreadable signs and covers. Only fully functioning robots and systems can be put back into operation.

Common troubleshooting ideas

1. Robot automatically shuts down

The common reason is triggered by temperature monitoring. Continuous high load, high ambient temperature, poor heat dissipation, or abnormal fan can all cause it. Environmental temperature, load cycle, fan speed, and exhaust duct should be checked. After cooling, it can be restarted, but the root cause needs to be investigated.

2. Safety stop 1 frequently triggered

Check if the enable switch is released or fully pressed; Whether to switch the operating mode; Has the local/external emergency stop been pressed; Is the safety door open; Whether the operation safety signal is lost; Is there any error in the safety controller. After resetting the emergency stop, the automatic mode cannot be restored solely by closing the safety door. Additional devices such as confirmation buttons must first reset the operation safety signal and confirm that there are no people in the danger zone.

3. Low fan speed or clean room alarm

Check if the WorkVisual I/O mapping is correct: Out7.Output, In1.Input. Check the control box 2A fuse, 24 VDC power supply, fan connector, exhaust duct for blockage, and fan for dust accumulation. If the speed is below 2200 rpm or decreases by more than 25%, the fan should be replaced. Abnormal fan operating noise should also be included in the annual inspection.

4. Emergency stop cannot be reset or the enable is invalid

Confirm that the smartPAD connection is reliable. If smartPAD is configured as pluggable, the system may not have a local emergency stop, and at least one external emergency stop must be accessible at any time. Check external emergency stop, external safety stop, safety output, and key switch. If the enable switch is stuck in the middle position, you can press another enable switch to the bottom or press emergency stop.

5. Abnormal stopping distance or braking

Perform brake testing and check the braking torque of each axle. Abnormal stopping distance may be caused by brake wear, overheating, contamination, damage, load changes, or excessive speed. Trigger axis specific or Cartesian workspace monitoring through safety monitoring and evaluate measurement data using a Data Recorder. Stop checking the distance at least once a year.

6. Communication or cable issues

Check if WX55, WX65, WXE1 are connected correctly and locked; Whether the cable can withstand tension and friction; Is the bending radius sufficient; Is it inside the metal conduit; Are shielding and EMC measures in place. The robot controller must not be plugged or unplugged during operation.

7. Coordinate display deviation of 35 mm

This is caused by the lifting of the base ring. When using the world base and displaying the actual position of Descartes, a deviation of 35 mm needs to be considered in the positive Z direction.

Replacing robots, disabling and storing them

Before replacing the robot, ensure that the installation/removal position is freely accessible and there are no system component hazards. Removal steps: Fix the robot, remove tools and equipment, power on and move to the transport position, fix again, close the controller, loosen and unplug the connecting cable, remove 4 hexagon socket bolts and locating pins, protect the connector and hose from contamination, lift the robot together with the LBR CR base ring, and place it in the transport container.

The installation steps are consistent with the previous installation: insert the positioning pin, place the base ring, insert the positioning pin, lower the robot vertically, install 4 bolts and gradually tighten them diagonally. After 100 hours, tighten them again, connect the exhaust duct, data cable, grounding conductor, installation tools, check the cables, and connect the energy supply.

Shutdown storage requirements: Choose a dry, dust-free, temperature fluctuation free, wind and airflow free, and condensation free location. Use coverings that will not detach on their own and can withstand environmental conditions. Loose parts must not be left on the robot. Avoid direct sunlight. Comply with the allowed storage temperature. Store in transportation location, clean and dry, inspect inside and outside, remove foreign objects and corrosion, install cover plate and check sealing, seal electrical connections and hose connections, and place in transportation container. Classify by material during disposal: aluminum outer structure, base ring, control box shell; Stainless steel shielding plate, screws, washers; Copper cable; Steel screws and pins; Electrical components are treated as electronic waste; The motor is not disassembled; Plastic ABS, elastomers, PA, PUR/PVC/rubber, etc. should be disposed of according to the labeling.