KUKA Robots LBR iiwa 7 R800, LBR iiwa 14 R820 Operating instructions

Product Description

The complete robot system consists of a robotic arm body, KUKA Sunrise Cabinet control cabinet, smartPAD teaching pendant, connecting cables, software, and optional accessories.

LBR iiwa ontology characteristics

7-axis redundant degree of freedom articulated arm lightweight robot, with all drive units and power cables built into the body.

Each axis is equipped with multiple sensors: axis travel sensor, torque sensor, and temperature sensor. The robot will automatically shut down under continuous heavy load and high temperature environment when the temperature exceeds the limit, and can be restarted without additional measures after cooling down.

Body structure: 2-axis built-in wrist (A6/A7 built-in motor), aluminum joint module, base frame. Base ring and fan assembly without CR version.

All motor connectors are plug-in connectors, and all cables have built-in wiring.

Installation methods supported: ground and ceiling lifting, side wall hanging (CR clean version only supports ground installation).

Technical Data

LBR iiwa 7 R800

Parameter values

7 axes fully controlled

Maximum arm span 800   mm

The weight of the body is about 23.9 kg

Rated load 7   kg

Repetitive positioning accuracy ± 0.1 mm (ISO9283)

Protection level: IP54 for the whole machine

Noise<75   dB (A)

Install floor/ceiling/wall mounted

Operating temperature range of 5-45 ℃; Storage and transportation at 0-45 ℃; Humidity 20-80%

Rated moment of inertia: 0.3   kg · m ²; Robots are not allowed to add additional loads; The center of gravity of the load is based on the A7 flange end face; Provide a load curve diagram, and both the load mass and moment of inertia must be checked. The selection of load and medium flange is strongly related.

Base load (ground installation): maximum vertical force 524N, maximum horizontal force 240N.

LBR iiwa 14 R820

7-axis, rated load 14   kg; maximum arm span 820   mm; overall IP54; Support ground installation, lifting, and wall hanging.

The rated moment of inertia is 0.3 kg · m ², and no additional load is allowed;

Base load (ground mounted): maximum vertical force 541.2   N, maximum overturning moment 281.6   Nm, maximum torque of A1 axis 172.6   Nm.

Shutdown distance and shutdown time (safety parameters)

Definition

Shutdown distance: the angle at which the shaft rotates from the moment the shutdown signal is triggered to a complete stop;

Shutdown time: the time it takes for the shutdown signal to trigger and come to a complete stop;

The document only provides the A1-A4 high inertia axis and multi axis composite motion, resulting in a larger actual stopping distance; Testing is based on PTP point-to-point motion.

Shutdown category

STOP 0: Cut off the drive and apply the brake;

STOP 1 (Class 1 path keeps stopping): Slow down and stop along the original trajectory, and cut off the driving brake after stopping.

Influencing variables: load mass m, arm extension (0-100%), program speed POV%. The manual provides a large number of curve graphs.

Tip: The manual values are the reference average values obtained from simulation and testing; Due to the influence of internal and external factors such as braking torque, the actual project must measure the stopping distance/time under real working conditions. The brake will wear out, which is related to the number of STOP0 triggers.

Safety Chapter

Legal Framework and Responsibilities

Even if all instructions are followed, the risk of personal injury and equipment damage cannot be completely ruled out.

Without authorization from KUKA, any robot modification is prohibited; Any damage caused by third-party tools or software shall be the responsibility of the integrator/user.

Robots must be operated by personnel who are in good condition, designated for their intended use, and aware of the risks involved; Safety faults must be dealt with immediately; EC conformity/assembly declaration is required.

Safety Features

Safety level: EN ISO13849-1 Cat.3 PL d; EN 62061 SIL2。

Prerequisite: All safety related mechanical/electromechanical components shall be tested upon start-up and retested at least once every 12 months; The SISTEMA security library can be downloaded from the official website.

Core Terminology

Workplace, Danger zone (=workspace+parking distance), Safety zone;

STOP0 and STOP1 paths remain stationary; CRR reset fallback mode;

T1 manual deceleration mode (nominal ≤ 250 mm/s, standard configuration this 250mm/s is not a safety monitoring speed limit, safety monitoring requires configuring safety options); T2 manual high-speed; AUT automatic mode.

Built in permanent safety function: teach pendant emergency stop, teach pendant three gear enable switch.

Configurable external security features: external emergency stop, external path maintenance safety stop, external enable, external safety operation stop; Axis/Cartesian workspace monitoring, speed monitoring, stationary monitoring, axis torque monitoring, collision detection.

Shutdown trigger source: Release the enable, fully press the enable (panic position), emergency stop press, safety door open, overspeed, collision, torque exceeding limit, etc.

Teaching pendant enable switch with three levels: not pressed, middle effective gear, fully pressed (panic mode); Release/fully press will trigger the STOP1 path to maintain shutdown. It is strictly prohibited to use tape to fix the enable switch.

Operator safety signal is used to monitor safety protection doors; In T2 and AUT modes, the opening of the protective door triggers STOP1; T1 mode does not evaluate this signal by default.

Operation mode description

Mode Function Description

T1 programming demonstration test; Jogging up to 250 mm/s; Manual drag without hard speed limit, monitored by safety configuration

T2 program testing, allowing high speed; Do not click to teach

AUT automatic running program; Do not jog

After the CRR safety controller triggers a shutdown, the mobile robot can be reset

Protective equipment, safety measures, and applicable standards

Responsibilities of system integrator: risk assessment, implementation of security measures, issuance of EC conformity declaration, CE marking, and writing of system operation manual.

Physical protection: Safety fences, safety barriers, etc. must be used; If there is no physical protection, all requirements for EN ISO10218 collaborative robots must be met.

Functional testing: A complete set of safety function tests must be completed every time the system is started/re debugged;

Brake test: Under the premise of no risk assessment, it is necessary to start debugging and perform brake tests daily during daily operation; Brake wear will reduce braking performance.

After modifying hardware, software, and parameters, all programs must be tested in T1 mode.

After the robot loses power, the brake may still fail and there is a risk of the robotic arm falling; During maintenance, it is necessary to place the robotic arm in a non falling position and provide mechanical support if necessary.

List the complete set of EU machinery EMC、 List of Robot Safety Standards.

Project Planning

Installation method: Rack installation with centering positioning pin, supporting ground installation, lifting, and wall mounting.

7   R800: 4 M8 × 30-8.8 hexagon socket screws, torque 23   Nm; locating pin 6 × 12; Hole position C184.

14   R820: 4 M10 × 35-8.8 hexagon socket screws, torque 45   Nm; locating pin 6 × 12; Hole position C216.

Cable: Robot side interface A1 is connected to a power+signal composite cable; The minimum fixed bending radius for cable laying should be ≥ 45   mm; cables should avoid pulling and wear, and it is recommended to use metal cable trays for wiring to meet EMC requirements.

Important: After 100 hours of operation, it is necessary to use a torque wrench to diagonally tighten the base fixing bolts.

Transportation

Original factory transportation packaging must be used, and the robot needs to be moved to the designated transportation posture (specific axis angles) to avoid overturning.

Two types of transport box sizes, compatible with both robots.

Before disassembling the base bolts, the robot must be placed in a transport position, which poses a risk of tipping over.

Startup and Re Debugging

Installation steps: Pre install the positioning pin → vertically hang the robot body → diagonally tighten the base bolts step by step; Tighten the torque after 100 hours of operation.

Cable docking, check that the cables are not pulled or rubbed; Installation tools;

Perform all safety function checks before startup to confirm that the base strength meets the load requirements.

Maintenance

According to the prescribed operating conditions, there are no scheduled maintenance projects for the robot body.

Robot Cleaning

Only solvent-free water-soluble cleaning agents are allowed; Prohibit flammable and highly corrosive cleaning agents; Prohibit high-pressure water guns, steam cleaning machines, and refrigerant cleaning.

Prevent cleaning agents from infiltrating mechanical and electrical components;

Press the emergency stop button to lock the robot before cleaning; After cleaning, restore the protective label cover plate.

Maintenance

The main body has not been designed for on-site maintenance; Robot body malfunction requires contacting KUKA customer support, and on-site disassembly of the body joint module is not allowed.

Discontinuation, Storage, and Scrap Disposal

Shutdown and dismantling: The robot switches transportation posture, dismantling tools, cutting off power, unplugging cables, dismantling base bolts, protecting connectors, and placing them in transportation containers.

Long term storage conditions: dry and dust-free, reduce temperature fluctuations, avoid condensation, and avoid light; Sealed electrical connectors;

Scrap and dismantle: dispose of according to material classification; Joint modules, motors, circuit boards and other electronic components are prohibited from being disassembled by themselves and should be disposed of as electronic waste.

KUKA Services

Contact information for global KUKA branch offices; Repair report requires preparation of robot model, serial number, controller version, KRCDiag diagnostic package, project files, and description of fault symptoms.

Comparison Table of Core Differences between Standard LBR iiwa V8 and CR Clean Edition

Project LBR iiwa (Standard V8) LBR iiwa CR Clean V3

Fan system without built-in fan base ring, built-in exhaust fan, matching control box

Installation methods include ground installation, hoisting, wall mounting, and only ground installation

Base height compensation without base ring lifting in Z direction+35mm, coordinate system needs to be compensated

The air duct interface does not require customers to provide their own Φ 120   mm exhaust ducts, and it is strictly prohibited to start without ducts

The software does not require fan IO configuration. WorkVisual imports the fan module and writes a background fan speed monitoring program

Body weight 7R800: 23.9 kg 7R800 CR: 26.1 kg (adding CR kit)

Applicable environment: General industrial environment, clean room (particle monitoring environment)